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KOMATSU WA320-8E0 WHEEL LOADER SHOP MANUAL SEN06792-06 – PDF DOWNLOAD
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KOMATSU WA320-8E0 WHEEL LOADER SHOP MANUAL SEN06792-06 – PDF DOWNLOAD
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KOMATSU WA320-8E0 WHEEL LOADER SHOP MANUAL SEN06792-06 – PDF DOWNLOAD
Language : English
Pages : 3500
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA320-8E0 WHEEL LOADER SHOP MANUAL SEN06792-06 – PDF DOWNLOAD
Cover........................................................................................................................................................ 1 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: WA320-8E0............................................................................................................ 105 Specifications.................................................................................................................................. 107 Specification: WA320-8E0.................................................................................................................... 107 Weight Table.................................................................................................................................... 112 Weight Table: WA320-8E0..................................................................................................................... 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................................................................................................................... 377 Final Drive................................................................................................................................. 381 Combination Switch.......................................................................................................................... 383 Work Equipment System............................................................................................................................... 387 Layout Drawing of Work Equipment System......................................................................................................... 387 Work Equipment Control System................................................................................................................... 389 Work Equipment Lever Operation Function..................................................................................................... 389 PZ Auto Tilt-in Compensation Control Function............................................................................................... 389 Work Equipment Lock System...................................................................................................................... 390 Work Equipment Lock System Diagram (Applicable Machine: 86025 to 87648)..................................................................... 390 Work Equipment Lock System Diagram (Applicable Machine: 87649 and Up)....................................................................... 390 Function of Work Equipment Lock System...................................................................................................... 391 Bucket Positioner System........................................................................................................................ 392 Bucket Positioner System Diagram............................................................................................................ 392 Function of Bucket Positioner System........................................................................................................ 392 Operation of Bucket Positioner System....................................................................................................... 394 Fork Positioner System.......................................................................................................................... 396 Fork Positioner System Diagram.............................................................................................................. 396 Function of Fork Positioner System.......................................................................................................... 396 Operation of Fork Positioner System......................................................................................................... 397 Remote Positioner System........................................................................................................................ 400 Remote Boom Positioner System Diagram....................................................................................................... 400 Function of Remote Boom Positioner System................................................................................................... 400 ECSS............................................................................................................................................ 403 ECSS Diagram................................................................................................................................ 403 Function of ECSS............................................................................................................................ 403 Operation of ECSS........................................................................................................................... 403 Component Parts of Work Equipment System........................................................................................................ 405 Self-Pressure Reducing Valve................................................................................................................ 405 Work Equipment Lock Solenoid Valve.......................................................................................................... 410 Pilot Circuit Accumulator................................................................................................................... 411 ECSS Circuit Accumulator.................................................................................................................... 412 Multifunction Mono-Lever.................................................................................................................... 413 Multifunction Mono-Lever PPC Valve.......................................................................................................... 415 Steering System..................................................................................................................................... 420 Layout Drawing of Steering System............................................................................................................... 420 Steering Column................................................................................................................................. 421 Structure of Steering Column................................................................................................................ 421 Component Parts of Steering System.............................................................................................................. 422 Priority Valve.............................................................................................................................. 422 Orbitrol Valve.............................................................................................................................. 425 Cushion Valve............................................................................................................................... 430 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 Brake Circuit Accumulator................................................................................................................... 445 Parking Brake Solenoid Valve................................................................................................................ 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.......................................................................................................... 460 Function of Auto-Greasing System................................................................................................................ 462 Auto-Greasing System............................................................................................................................ 463 Auto-Greasing Pump.......................................................................................................................... 463 Undercarriage and Frame............................................................................................................................. 464 Frame, Axle Mount and Center Hinge Pin.......................................................................................................... 464 Structure of Frame, Axle Mount and Center Hinge Pin......................................................................................... 464 Function of Frame, Axle Mount and Center Hinge Pin.......................................................................................... 465 Tires........................................................................................................................................... 467 Features of Radial Tire When Compared with Bias Tire........................................................................................ 467 Structure of Radial Tire.................................................................................................................... 467 Function of Radial Tire..................................................................................................................... 468 Structure of Bias Tire...................................................................................................................... 468 Function of Bias Tire....................................................................................................................... 468 Work Equipment...................................................................................................................................... 469 Structure of Work Equipment..................................................................................................................... 469 Structure of Bucket............................................................................................................................. 470 CAB Related Parts................................................................................................................................... 471 ROPS CAB........................................................................................................................................ 471 Structure of ROPS CAB....................................................................................................................... 471 Function of ROPS CAB........................................................................................................................ 471 CAB Mount....................................................................................................................................... 472 Structure of CAB Mount...................................................................................................................... 472 Function of CAB Mount....................................................................................................................... 472 20 Standard Value Table................................................................................................................................. 473 Table of Contents................................................................................................................................... 474 Abbreviation List................................................................................................................................... 475 Standard Value Table for Engine..................................................................................................................... 481 Standard Value Table for Engine: WA320-8E0...................................................................................................... 481 Standard Value Table for Machine.................................................................................................................... 485 Standard Value Table for Machine: WA320-8E0..................................................................................................... 485 Machine Posture and Procedures to Measure Performance........................................................................................... 498 30 Testing and Adjusting................................................................................................................................ 501 Table of Contents................................................................................................................................... 502 Precautions Before Work............................................................................................................................. 506 Abbreviation List................................................................................................................................... 507 Related Information on Testing and Adjusting........................................................................................................ 513 Differences In Machine Monitor Symbols.......................................................................................................... 513 Tools for Testing and Adjusting................................................................................................................. 514 Sketch of Tools for Testing and Adjusting....................................................................................................... 523 Engine and Cooling System........................................................................................................................... 524 Examine Engine Speed............................................................................................................................ 524 How to Examine Engine Speed................................................................................................................. 524 Examine Boost Pressure.......................................................................................................................... 527 How to Examine Boost Pressure on Machine Monitor............................................................................................ 527 How to Examine Boost Pressure by Testing Tool............................................................................................... 528 Examine Exhaust Gas Temperature................................................................................................................. 530 How to Examine Exhaust Gas Temperature...................................................................................................... 530 Examine Exhaust Gas Color....................................................................................................................... 532 How to Examine Exhaust Gas Color with the Handy Smoke Checker............................................................................... 532 How to Examine Exhaust Gas Color with Smoke Meter........................................................................................... 534 Examine Mass Air Flow and Temperature Sensor.................................................................................................... 536 How to Examine Mass Air Flow and Temperature Sensor......................................................................................... 536 Examine and Adjust Valve Clearance.............................................................................................................. 538 How to Examine Valve Clearance.............................................................................................................. 538 How to Adjust Valve Clearance............................................................................................................... 539 Examine Compression Pressure.................................................................................................................... 540 How to Examine Compression Pressure......................................................................................................... 540 Examine Blowby Pressure......................................................................................................................... 545 How to Examine Blowby Pressure.............................................................................................................. 545 Examine Engine Oil Pressure..................................................................................................................... 548 How to Examine Engine Oil Pressure.......................................................................................................... 548 Examine EGR Valve and VGT Oil Pressure.......................................................................................................... 550 How to Examine EGR Valve and VGT Oil Pressure............................................................................................... 550 Examine Fuel Pressure........................................................................................................................... 552 How to Examine Fuel Pressure................................................................................................................ 553 Examine Fuel Discharge, Return and Leakage...................................................................................................... 558 How to Examine Fuel Discharge, Return, and Leakage.......................................................................................... 559 Bleed Air from Fuel System...................................................................................................................... 565 How to Bleed Air from Fuel System........................................................................................................... 565 Examine Fuel Circuit for Leakage................................................................................................................ 567 How to Examine Fuel System for Leakage...................................................................................................... 567 Handle Cylinder Cut-out Mode Operation.......................................................................................................... 569 Handle No-Injection Cranking Operation.......................................................................................................... 570 Examine KDPF, SCR and Muffler Stack for Looseness and Damage.................................................................................... 571 How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage......................................................................... 571 Examine Installed Condition of Cylinder Heads and Manifolds..................................................................................... 572 How to Examine Installed Condition of Cylinder Heads and Manifolds.......................................................................... 572 Examine Engine Piping for Damage and Looseness.................................................................................................. 573 How to Examine Engine Piping for Damage and Looseness....................................................................................... 573 Examine and Adjust Air Conditioner Compressor Belt Tension...................................................................................... 574 How to Examine Air Conditioner Compressor Belt.............................................................................................. 574 How to Adjust Air Conditioner Compressor Belt............................................................................................... 574 Examine Alternator Belt......................................................................................................................... 576 How to Examine Alternator Belt.............................................................................................................. 576 Examine Automatic Tensioner..................................................................................................................... 578 How to Examine Automatic Tensioner.......................................................................................................... 578 Write Correction for Ash in Soot Accumulation to Engine Controller.............................................................................. 581 How to Write Correction for Ash in Soot Accumulation to Engine Controller................................................................... 581 Examine SCR Related Functions................................................................................................................... 582 Examine DEF Pump Raised Pressure............................................................................................................ 586 Examine Injection Volume from DEF Injector.................................................................................................. 589 Examine DEF Line Heater Relay 1............................................................................................................. 594 Examine DEF Line Heater Relay 2............................................................................................................. 598 Examine DEF Pump Heater Relay............................................................................................................... 602 Examine DEF Tank Heater Valve............................................................................................................... 606 Examine SCR Denitration Efficiency.......................................................................................................... 610 Clean DEF Tank.................................................................................................................................. 614 How to Clean DEF Tank....................................................................................................................... 614 Clean DEF Pump.................................................................................................................................. 618 How to Clean DEF Pump....................................................................................................................... 618 Power Train......................................................................................................................................... 624 Examine and Adjust HST Oil Pressure............................................................................................................. 624 How to Examine HST Oil Pressure............................................................................................................. 624 How to Adjust HST Oil Pressure.............................................................................................................. 626 Examine the Control Pressure of Transfer Clutch................................................................................................. 628 How to Examine the Control Pressure of Transfer Clutch...................................................................................... 628 Examine Drive Shaft for Looseness, Backlash, and Damage......................................................................................... 630 How to Examine Drive Shaft for Looseness, Backlash, and Damage.............................................................................. 630 Steering System..................................................................................................................................... 631 Examine Steering Wheel.......................................................................................................................... 631 How to Examine Steering Wheel............................................................................................................... 631 Examine and Adjust Steering Circuit Oil Pressure................................................................................................ 633 How to Examine Steering Circuit Oil Pressure with the Machine Monitor....................................................................... 633 How to Examine Steering Circuit Pressure with Test Tools.................................................................................... 634 How to Adjust Steering Circuit Oil Pressure................................................................................................. 634 Bleed Air from Steering Cylinder Circuit........................................................................................................ 636 How to Bleed Air from Steering Cylinder Circuit............................................................................................. 636 Brake System........................................................................................................................................ 637 Release Remained Pressure in Brake Accumulator Circuit.......................................................................................... 637 How to Release Remained Pressure in Brake Accumulator Circuit............................................................................... 637 Examine Wheel Brake Oil Pressure................................................................................................................ 638 How to Examine Wheel Brake Oil Pressure..................................................................................................... 638 Examine and Adjust Brake Accumulator Charge Pressure............................................................................................ 640 How to Examine Brake Accumulator Charge Pressure............................................................................................ 640 How to Adjust Brake Accumulator Charge Pressure............................................................................................. 641 Bleed Air from Brake Circuit.................................................................................................................... 642 How to Bleed Air from Brake Circuit......................................................................................................... 642 Examine Brake Performance....................................................................................................................... 644 How to Examine Brake Performance............................................................................................................ 644 Examine Brake Pedal............................................................................................................................. 645 How to Examine Brake Pedal.................................................................................................................. 645 Examine Pressure Decrease of Wheel Brake........................................................................................................ 646 How to Examine Pressure Decrease of Wheel Brake............................................................................................. 647 Examine Wear of Wheel Brake Disc................................................................................................................ 649 How to Examine Wear of Wheel Brake Disc..................................................................................................... 649 Examine Parking Brake Oil Pressure.............................................................................................................. 651 How to Examine Parking Brake Oil Pressure................................................................................................... 651 Examine Parking Brake Performance............................................................................................................... 653 How to Examine Parking Brake Performance.................................................................................................... 653 Release Parking Brake Manually.................................................................................................................. 654 How to Release Parking Brake Manually....................................................................................................... 654 Examine Wear Volume of Parking Brake Disc....................................................................................................... 655 How to Examine Wear Quantity of Parking Brake Disc.......................................................................................... 655 Hydraulic System.................................................................................................................................... 656 Release Remained Pressure from Work Equipment Circuit........................................................................................... 656 How to Release Remained Pressure from Work Equipment Circuit................................................................................ 656 Examine and Adjust Work Equipment Oil Pressure.................................................................................................. 658 How to Examine Work Equipment Oil Pressure.................................................................................................. 658 How to Adjust Work Equipment Oil Pressure................................................................................................... 662 Examine and Adjust Work Equipment PPC Oil Pressure.............................................................................................. 664 How to Examine Work Equipment PPC Oil Pressure.............................................................................................. 664 How to Adjust Work Equipment PPC Oil Pressure............................................................................................... 666 Bleed Air from Work Equipment Circuit........................................................................................................... 668 How to Bleed Air from Work Equipment Circuit................................................................................................ 668 Examine Cooling Fan Speed....................................................................................................................... 670 How to Examine Cooling Fan Speed............................................................................................................ 670 Examine Cooling Fan Circuit Oil Pressure........................................................................................................ 671 How to Examine Cooling Fan Circuit Oil Pressure............................................................................................. 671 Bleed Air from Cooling Fan Circuit.............................................................................................................. 674 How to Bleed Air from Cooling Fan Circuit................................................................................................... 674 Examine ECSS Accumulator Nitrogen Gas Pressure and Charge Accumulator with Nitrogen Gas......................................................... 676 How to Examine ECSS Accumulator Nitrogen Gas Pressure....................................................................................... 676 How to Charge ECSS Accumulator with Nitrogen Gas............................................................................................ 678 Work Equipment...................................................................................................................................... 682 Examine and Adjust Bucket Positioner............................................................................................................ 682 How to Examine Bucket Positioner............................................................................................................ 682 How to Adjust Bucket Positioner............................................................................................................. 682 Examine and Adjust Boom Potentiometer Lever..................................................................................................... 684 How to Examine Boom Potentiometer Lever..................................................................................................... 684 How to Adjust Boom Potentiometer Lever...................................................................................................... 684 CAB Related Parts................................................................................................................................... 685 Examine Directional Lever....................................................................................................................... 685 How to Examine Directional Lever............................................................................................................ 685 Examine Multifunction Mono-Lever................................................................................................................ 686 How to Examine Multifunction Mono-Lever..................................................................................................... 686 Examine Accelerator Pedal....................................................................................................................... 688 How to Examine Accelerator Pedal............................................................................................................ 688 Adjust Play of Operator Seat.................................................................................................................... 690 How to Adjust Play of Operator Seat......................................................................................................... 690 Electrical System................................................................................................................................... 691 Set and Adjust Each Equipment................................................................................................................... 691 Set and Operate Machine Monitor................................................................................................................. 695 Operator Mode............................................................................................................................... 699 Function to Show Technician Identification Status Screen.................................................................................... 699 Function to Show Operator Identification Input Screen....................................................................................... 699 Examine Function by LCD (Liquid Crystal Display)............................................................................................ 700 Examine Function of Service Meter and Odometer.............................................................................................. 701 How to Set Usage Limitation and Change Maintenance Password................................................................................. 701 Service Mode................................................................................................................................ 705 How to Operate Service Mode................................................................................................................. 705 How to See Pre-defined Monitoring Information............................................................................................... 708 How to Examine Self-Define Monitor Information.............................................................................................. 715 Abnormality Record Menu..................................................................................................................... 727 How to See Maintenance Record............................................................................................................... 732 Maintenance Mode Setting.................................................................................................................... 734 How to Set Phone Number Entry............................................................................................................... 739 Default Menu................................................................................................................................ 741 Diagnostic Tests Menu....................................................................................................................... 756 Adjustment Menu............................................................................................................................. 767 No-Injection Cranking Operation............................................................................................................. 801 KOMTRAX Settings Menu....................................................................................................................... 803 How to Show Service Message................................................................................................................. 805 How to Start Up KOMTRAX System.................................................................................................................. 807 Adjust Rearview Camera Angle.................................................................................................................... 813 How to Adjust Rearview Camera Angle......................................................................................................... 813 Set Region of Bluetooth(R) Compatible Radio..................................................................................................... 815 How to Set Region of Bluetooth(R) Compatible Radio.......................................................................................... 815 Handle Voltage Circuit of Engine Controller..................................................................................................... 817 Handle Battery Disconnect Switch................................................................................................................ 818 Examine Diodes.................................................................................................................................. 819 How to Examine Diodes by Digital Tester..................................................................................................... 819 How to Examine Diodes by Analog Tester...................................................................................................... 819 Auto-Greasing Device................................................................................................................................ 820 Bleed the Air in Auto-Greasing System........................................................................................................... 820 How to Bleed the Air in Auto-Greasing System................................................................................................ 820 Change Lubrication Time and Lubrication Interval................................................................................................ 823 How to Change Lubrication Time and Lubrication Interval..................................................................................... 824 Pm Clinic........................................................................................................................................... 826 Pm Clinic Service............................................................................................................................... 826 Pm Clinic Check Sheet: WA320-8E0............................................................................................................ 828 40 Troubleshooting...................................................................................................................................... 835 Table of Contents................................................................................................................................... 836 Precautions Before Work............................................................................................................................. 848 Abbreviation List................................................................................................................................... 849 Related Information to Troubleshooting.............................................................................................................. 855 General Troubleshooting Points.................................................................................................................. 855 Troubleshooting Points for Urea SCR System...................................................................................................... 856 Sequence of Events in Troubleshooting........................................................................................................... 868 Checks Before Troubleshooting................................................................................................................... 870 Inspection Procedure Before Troubleshooting..................................................................................................... 872 Walk-Around Check........................................................................................................................... 872 Test in Accordance with Testing Procedure....................................................................................................... 874 Examine Fuel Level and Type................................................................................................................. 874 Examine for Impure Ingredient in Fuel....................................................................................................... 874 Examine DEF Level and Type.................................................................................................................. 875 Examine Fuel Prefilter...................................................................................................................... 875 Examine Fuel Main Filter.................................................................................................................... 877 Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type................................................................................. 878 Examine Coolant Level (Reservoir Tank)...................................................................................................... 879 Examine Air Cleaner Clogging................................................................................................................ 880 Clean Outer Element......................................................................................................................... 881 Replace Element............................................................................................................................. 882 Examine Hydraulic Oil Level................................................................................................................. 884 Examine Hydraulic Oil Strainer.............................................................................................................. 884 Examine Hydraulic Oil Filter................................................................................................................ 887 Examine the Oil Level in the Transfer Case.................................................................................................. 887 Examine Oil Level in Front Axle Case........................................................................................................ 889 Examine Oil Level in Rear Axle Case......................................................................................................... 890 Bleed Air from Fuel System.................................................................................................................. 890 Bleed Air from Hydraulic System............................................................................................................. 890 How to Examine Electric Equipment........................................................................................................... 891 Preparation for Troubleshooting of Electrical System............................................................................................ 896 Procedure for Troubleshooting................................................................................................................... 904 Symptom and Troubleshooting Numbers............................................................................................................. 906 Information Shown in Troubleshooting Table...................................................................................................... 910 How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness................................................................. 912 Connector List and Layout (Applicable Machine: 85001 to 87648).................................................................................. 915 Connector List and Layout (Applicable Machine: 87649 and Up).................................................................................... 932 Connector Contact Connection Table.............................................................................................................. 950 T-Branch Box and T-Branch Adapter Table......................................................................................................... 990 Fuse Location Table............................................................................................................................. 996 Precautions When You Clean and Replace KDPF (KCSF and KDOC)..................................................................................... 999 Prepare Troubleshoot Machine Monitor............................................................................................................1003 Procedure to Make Harness Checker on Machine Monitor LCD Unit...................................................................................1005 Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])............................................................1011 Failure Code Table..............................................................................................................................1013 Troubleshooting by Failure Code (Display of Code)...................................................................................................1034 Failure Code [2F00MA]...........................................................................................................................1034 Failure Code [2F00MB]...........................................................................................................................1037 Failure Code [2G42ZG]...........................................................................................................................1039 Failure Code [2G43ZG]...........................................................................................................................1041 Failure Code [6091NX]...........................................................................................................................1043 Failure Code [7RHYKA]...........................................................................................................................1045 Failure Code [7RHYKB]...........................................................................................................................1047 Failure Code [7RHYKY]...........................................................................................................................1049 Failure Code [879AKA]...........................................................................................................................1051 Failure Code [879AKB]...........................................................................................................................1053 Failure Code [879BKA]...........................................................................................................................1055 Failure Code [879BKB]...........................................................................................................................1057 Failure Code [879CKA]...........................................................................................................................1059 Failure Code [879CKB]...........................................................................................................................1061 Failure Code [879DKZ]...........................................................................................................................1063 Failure Code [879EMC]...........................................................................................................................1065 Failure Code [879FMC]...........................................................................................................................1066 Failure Code [989FN1]...........................................................................................................................1067 Failure Code [989L00]...........................................................................................................................1068 Failure Code [989M00]...........................................................................................................................1069 Failure Code [989N00]...........................................................................................................................1070 Failure Code [A1U0N3]...........................................................................................................................1071 Failure Code [A1U0N4]...........................................................................................................................1073 Failure Code [AA10NX]...........................................................................................................................1075 Failure Code [AB00KE]...........................................................................................................................1077 Failure Code [AB00KY]...........................................................................................................................1079 Failure Code [AQ10N3]...........................................................................................................................1081 Failure Code [AS00N3]...........................................................................................................................1083 Failure Code [AS00R2]...........................................................................................................................1085 Failure Code [AS00R3]...........................................................................................................................1086 Failure Code [AS00R4]...........................................................................................................................1087 Failure Code [AS00R5]...........................................................................................................................1088 Failure Code [AS00R6]...........................................................................................................................1089 Failure Code [AS00ZK]...........................................................................................................................1090 Failure Code [AS10KM]...........................................................................................................................1091 Failure Code [AS10NR]...........................................................................................................................1092 Failure Code [AS10NT]...........................................................................................................................1093 Failure Code [B@BAZG]...........................................................................................................................1094 Failure Code [B@BAZK]...........................................................................................................................1095 Failure Code [B@BCNS]...........................................................................................................................1097 Failure Code [B@BCZK]...........................................................................................................................1098 Failure Code [B@C6NS]...........................................................................................................................1100 Failure Code [B@CRNS]...........................................................................................................................1102 Failure Code [CA115]............................................................................................................................1103 Failure Code [CA122]............................................................................................................................1104 Failure Code [CA123]............................................................................................................................1106 Failure Code [CA131]............................................................................................................................1108 Failure Code [CA132]............................................................................................................................1110 Failure Code [CA144]............................................................................................................................1113 Failure Code [CA145]............................................................................................................................1115 Failure Code [CA153]............................................................................................................................1117 Failure Code [CA154]............................................................................................................................1120 Failure Code [CA187]............................................................................................................................1122 Failure Code [CA221]............................................................................................................................1124 Failure Code [CA222]............................................................................................................................1126 Failure Code [CA227]............................................................................................................................1128 Failure Code [CA234]............................................................................................................................1129 Failure Code [CA238]............................................................................................................................1130 Failure Code [CA239]............................................................................................................................1132 Failure Code [CA249]............................................................................................................................1134 Failure Code [CA256]............................................................................................................................1136 Failure Code [CA271]............................................................................................................................1138 Failure Code [CA272]............................................................................................................................1140 Failure Code [CA322]............................................................................................................................1142 Failure Code [CA323]............................................................................................................................1144 Failure Code [CA324]............................................................................................................................1146 Failure Code [CA325]............................................................................................................................1148 Failure Code [CA331]............................................................................................................................1150 Failure Code [CA332]............................................................................................................................1152 Failure Code [CA343]............................................................................................................................1154 Failure Code [CA351]............................................................................................................................1155 Failure Code [CA352]............................................................................................................................1156 Failure Code [CA356]............................................................................................................................1159 Failure Code [CA357]............................................................................................................................1161 Failure Code [CA386]............................................................................................................................1164 Failure Code [CA428]............................................................................................................................1165 Failure Code [CA429]............................................................................................................................1167 Failure Code [CA431]............................................................................................................................1169 Failure Code [CA432]............................................................................................................................1172 Failure Code [CA435]............................................................................................................................1176 Failure Code [CA441]............................................................................................................................1178 Failure Code [CA442]............................................................................................................................1180 Failure Code [CA449]............................................................................................................................1181 Failure Code [CA451]............................................................................................................................1182 Failure Code [CA452]............................................................................................................................1184 Failure Code [CA488]............................................................................................................................1186 Failure Code [CA515]............................................................................................................................1187 Failure Code [CA516]............................................................................................................................1189 Failure Code [CA553]............................................................................................................................1191 Failure Code [CA555]............................................................................................................................1192 Failure Code [CA556]............................................................................................................................1193 Failure Code [CA559]............................................................................................................................1194 Failure Code [CA595]............................................................................................................................1197 Failure Code [CA687]............................................................................................................................1198 Failure Code [CA689]............................................................................................................................1200 Failure Code [CA691]............................................................................................................................1203 Failure Code [CA692]............................................................................................................................1205 Failure Code [CA697]............................................................................................................................1207 Failure Code [CA698]............................................................................................................................1208 Failure Code [CA731]............................................................................................................................1209 Failure Code [CA778]............................................................................................................................1211 Failure Code [CA1117]...........................................................................................................................1216 Failure Code [CA1664]...........................................................................................................................1217 Failure Code [CA1669]...........................................................................................................................1219 Failure Code [CA1673]...........................................................................................................................1220 Failure Code [CA1677]...........................................................................................................................1221 Failure Code [CA1678]...........................................................................................................................1222 Failure Code [CA1682]...........................................................................................................................1223 Failure Code [CA1683]...........................................................................................................................1228 Failure Code [CA1684]...........................................................................................................................1230 Failure Code [CA1686]...........................................................................................................................1232 Failure Code [CA1691]...........................................................................................................................1233 Failure Code [CA1694]...........................................................................................................................1236 Failure Code [CA1695]...........................................................................................................................1239 Failure Code [CA1696]...........................................................................................................................1240 Failure Code [CA1712]...........................................................................................................................1242 Failure Code [CA1713]...........................................................................................................................1245 Failure Code [CA1714]...........................................................................................................................1247 Failure Code [CA1715]...........................................................................................................................1248 Failure Code [CA1776]...........................................................................................................................1249 Failure Code [CA1777]...........................................................................................................................1252 Failure Code [CA1843]...........................................................................................................................1255 Failure Code [CA1844]...........................................................................................................................1257 Failure Code [CA1879]...........................................................................................................................1260 Failure Code [CA1881]...........................................................................................................................1263 Failure Code [CA1883]...........................................................................................................................1265 Failure Code [CA1885]...........................................................................................................................1269 Failure Code [CA1887]...........................................................................................................................1271 Failure Code [CA1921]...........................................................................................................................1273 Failure Code [CA1922]...........................................................................................................................1276 Failure Code [CA1942]...........................................................................................................................1281 Failure Code [CA1993]...........................................................................................................................1282 Failure Code [CA2185]...........................................................................................................................1285 Failure Code [CA2186]...........................................................................................................................1287 Failure Code [CA2249]...........................................................................................................................1289 Failure Code [CA2271]...........................................................................................................................1290 Failure Code [CA2272]...........................................................................................................................1293 Failure Code [CA2288]...........................................................................................................................1296 Failure Code [CA2311]...........................................................................................................................1297 Failure Code [CA2349]...........................................................................................................................1298 Failure Code [CA2353]...........................................................................................................................1301 Failure Code [CA2357]...........................................................................................................................1303 Failure Code [CA2381]...........................................................................................................................1304 Failure Code [CA2382]...........................................................................................................................1307 Failure Code [CA2383]...........................................................................................................................1310 Failure Code [CA2386]...........................................................................................................................1313 Failure Code [CA2387]...........................................................................................................................1315 Troubleshooting Flowchart...................................................................................................................1319 Failure Code [CA2555]...........................................................................................................................1320 Failure Code [CA2556]...........................................................................................................................1323 Failure Code [CA2637]...........................................................................................................................1325 Failure Code [CA2639]...........................................................................................................................1327 Failure Code [CA2771]...........................................................................................................................1330 Failure Code [CA2777]...........................................................................................................................1336 Failure Code [CA2976]...........................................................................................................................1339 Failure Code [CA3133]...........................................................................................................................1341 Failure Code [CA3134]...........................................................................................................................1344 Failure Code [CA3135]...........................................................................................................................1346 Failure Code [CA3142]...........................................................................................................................1350 Failure Code [CA3143]...........................................................................................................................1351 Failure Code [CA3144]...........................................................................................................................1352 Failure Code [CA3146]...........................................................................................................................1354 Failure Code [CA3147]...........................................................................................................................1355 Failure Code [CA3148]...........................................................................................................................1356 Failure Code [CA3151]...........................................................................................................................1358 Failure Code [CA3165]...........................................................................................................................1364 Failure Code [CA3229]...........................................................................................................................1366 Failure Code [CA3231]...........................................................................................................................1368 Failure Code [CA3232]...........................................................................................................................1370 Failure Code [CA3235]...........................................................................................................................1374 Failure Code [CA3239]...........................................................................................................................1376 Failure Code [CA3241]...........................................................................................................................1379 Failure Code [CA3242]...........................................................................................................................1382 Failure Code [CA3251]...........................................................................................................................1385 Failure Code [CA3253]...........................................................................................................................1387 Failure Code [CA3254]...........................................................................................................................1390 Failure Code [CA3255]...........................................................................................................................1393 Failure Code [CA3256]...........................................................................................................................1397 Failure Code [CA3311]...........................................................................................................................1399 Failure Code [CA3312]...........................................................................................................................1401 Failure Code [CA3313]...........................................................................................................................1404 Failure Code [CA3314]...........................................................................................................................1405 Failure Code [CA3315]...........................................................................................................................1406 Failure Code [CA3316]...........................................................................................................................1409 Failure Code [CA3317]...........................................................................................................................1410 Failure Code [CA3318]...........................................................................................................................1411 Failure Code [CA3319]...........................................................................................................................1414 Failure Code [CA3321]...........................................................................................................................1415 Failure Code [CA3322]...........................................................................................................................1417 Failure Code [CA3419]...........................................................................................................................1420 Failure Code [CA3421]...........................................................................................................................1422 Failure Code [CA3497]...........................................................................................................................1424 Failure Code [CA3498]...........................................................................................................................1425 Failure Code [CA3543]...........................................................................................................................1426 Failure Code [CA3545]...........................................................................................................................1433 Failure Code [CA3547]...........................................................................................................................1435 Failure Code [CA3558]...........................................................................................................................1436 Failure Code [CA3559]...........................................................................................................................1438 Failure Code [CA3562]...........................................................................................................................1440 Failure Code [CA3563]...........................................................................................................................1442 Failure Code [CA3567]...........................................................................................................................1445 Failure Code [CA3568]...........................................................................................................................1448 Failure Code [CA3571]...........................................................................................................................1454 Failure Code [CA3572]...........................................................................................................................1456 Failure Code [CA3574]...........................................................................................................................1458 Failure Code [CA3575]...........................................................................................................................1461 Failure Code [CA3577]...........................................................................................................................1463 Failure Code [CA3578]...........................................................................................................................1465 Failure Code [CA3582]...........................................................................................................................1467 Failure Code [CA3583]...........................................................................................................................1475 Failure Code [CA3596]...........................................................................................................................1477 Failure Code [CA3649]...........................................................................................................................1480 Failure Code [CA3681]...........................................................................................................................1482 Failure Code [CA3682]...........................................................................................................................1487 Failure Code [CA3713]...........................................................................................................................1493 Failure Code [CA3717]...........................................................................................................................1496 Failure Code [CA3718]...........................................................................................................................1497 Failure Code [CA3725]...........................................................................................................................1498 Failure Code [CA3741]...........................................................................................................................1501 Failure Code [CA3748]...........................................................................................................................1502 Failure Code [CA3751]...........................................................................................................................1505 Failure Code [CA3755]...........................................................................................................................1507 Failure Code [CA3866]...........................................................................................................................1509 Failure Code [CA3867]...........................................................................................................................1513 Failure Code [CA3868]...........................................................................................................................1516 Failure Code [CA3899]...........................................................................................................................1520 Failure Code [CA3911]...........................................................................................................................1522 Failure Code [CA3912]...........................................................................................................................1526 Failure Code [CA3932]...........................................................................................................................1528 Failure Code [CA3933]...........................................................................................................................1530 Failure Code [CA3934]...........................................................................................................................1532 Failure Code [CA3935]...........................................................................................................................1535 Failure Code [CA3936]...........................................................................................................................1537 Failure Code [CA4151]...........................................................................................................................1539 Failure Code [CA4152]...........................................................................................................................1543 Failure Code [CA4155]...........................................................................................................................1547 Failure Code [CA4156]...........................................................................................................................1549 Failure Code [CA4157]...........................................................................................................................1552 Failure Code [CA4158]...........................................................................................................................1554 Failure Code [CA4159]...........................................................................................................................1555 Failure Code [CA4161]...........................................................................................................................1556 Failure Code [CA4162]...........................................................................................................................1559 Failure Code [CA4163]...........................................................................................................................1562 Failure Code [CA4164]...........................................................................................................................1564 Failure Code [CA4165]...........................................................................................................................1566 Failure Code [CA4166]...........................................................................................................................1568 Failure Code [CA4168]...........................................................................................................................1570 Failure Code [CA4169]...........................................................................................................................1573 Failure Code [CA4171]...........................................................................................................................1575 Failure Code [CA4249]...........................................................................................................................1578 Failure Code [CA4251]...........................................................................................................................1580 Failure Code [CA4259]...........................................................................................................................1582 Failure Code [CA4261]...........................................................................................................................1585 Failure Code [CA4277]...........................................................................................................................1588 Failure Code [CA4281]...........................................................................................................................1592 Failure Code [CA4459]...........................................................................................................................1595 Failure Code [CA4461]...........................................................................................................................1597 Failure Code [CA4658]...........................................................................................................................1600 Failure Code [CA4731]...........................................................................................................................1604 Failure Code [CA4732]...........................................................................................................................1605 Failure Code [CA4739]...........................................................................................................................1606 Failure Code [CA4768]...........................................................................................................................1607 Failure Code [CA4769]...........................................................................................................................1609 Failure Code [CA4842]...........................................................................................................................1611 Failure Code [CA4952]...........................................................................................................................1615 Failure Code [CA5115]...........................................................................................................................1617 Failure Code [CA5179]...........................................................................................................................1620 Failure Code [CA5181]...........................................................................................................................1622 Failure Code [CA5383]...........................................................................................................................1624 Failure Code [D103KA]...........................................................................................................................1626 Failure Code [D103KB]...........................................................................................................................1628 Failure Code [D103KY]...........................................................................................................................1630 Failure Code [D103MC]...........................................................................................................................1632 Failure Code [D104KA]...........................................................................................................................1634 Failure Code [D104KB]...........................................................................................................................1636 Failure Code [D104KY]...........................................................................................................................1638 Failure Code [D104MC]...........................................................................................................................1640 Failure Code [D110L4]...........................................................................................................................1642 Failure Code [D160KA]...........................................................................................................................1644 Failure Code [D160KY]...........................................................................................................................1646 Failure Code [D191KA]...........................................................................................................................1647 Failure Code [D191KB]...........................................................................................................................1649 Failure Code [D191KY]...........................................................................................................................1651 Failure Code [D192KA]...........................................................................................................................1652 Failure Code [D192KB]...........................................................................................................................1653 Failure Code [D192KY]...........................................................................................................................1654 Failure Code [D19JKZ]...........................................................................................................................1655 Failure Code [D1B0KA]...........................................................................................................................1657 Failure Code [D1B0KB]...........................................................................................................................1659 Failure Code [D1B0KY]...........................................................................................................................1661 Failure Code [D1B0MC]...........................................................................................................................1663 Failure Code [D1E6KA]...........................................................................................................................1665 Failure Code [D1E6KB]...........................................................................................................................1667 Failure Code [D1E6KY]...........................................................................................................................1669 Failure Code [D5ZHKA]...........................................................................................................................1671 Failure Code [D5ZHKB]...........................................................................................................................1673 Failure Code [D5ZHL6]...........................................................................................................................1675 Failure Code [D811MC]...........................................................................................................................1676 Failure Code [D862KA]...........................................................................................................................1677 Failure Code [D8ALKA]...........................................................................................................................1678 Failure Code [D8ALKB]...........................................................................................................................1680 Failure Code [D8AQK4]...........................................................................................................................1682 Failure Code [D8AQKR]...........................................................................................................................1686 Failure Code [D8G1KT]...........................................................................................................................1690 Failure Code [D8G6KT]...........................................................................................................................1691 Failure Code [DAF0KT]...........................................................................................................................1692 Failure Code [DAF0MB]...........................................................................................................................1693 Failure Code [DAF0MC]...........................................................................................................................1694 Failure Code [DAF3KK]...........................................................................................................................1695 Failure Code [DAF8KB]...........................................................................................................................1697 Failure Code [DAFDKB]...........................................................................................................................1698 Failure Code [DAFGMC]...........................................................................................................................1700 Failure Code [DAFLKA]...........................................................................................................................1701 Failure Code [DAFLKB]...........................................................................................................................1703 Failure Code [DAFQKR]...........................................................................................................................1705 Failure Code [DAJ0KK]...........................................................................................................................1710 Failure Code [DAJ0KT]...........................................................................................................................1713 Failure Code [DAJ0MC]...........................................................................................................................1714 Failure Code [DAJ1KA]...........................................................................................................................1715 Failure Code [DAJ2KK]...........................................................................................................................1717 Failure Code [DAJ2KT]...........................................................................................................................1720 Failure Code [DAJ4KB]...........................................................................................................................1723 Failure Code [DAJ4KZ]...........................................................................................................................1725 Failure Code [DAJ5KX] (Applicable Machine: 85001 to 87648)......................................................................................1727 Failure Code [DAJ5KX] (Applicable Machine: 87649 and Up)........................................................................................1729 Failure Code [DAJ6KX] (Applicable Machine: 85001 to 87648)......................................................................................1731 Failure Code [DAJ6KX] (Applicable Machine: 87649 and Up)........................................................................................1733 Failure Code [DAJ9KQ]...........................................................................................................................1735 Failure Code [DAJLKA]...........................................................................................................................1736 Failure Code [DAJLKB]...........................................................................................................................1738 Failure Code [DAJQKR]...........................................................................................................................1740 Failure Code [DAJRKR]...........................................................................................................................1745 Failure Code [DAJRMA]...........................................................................................................................1750 Failure Code [DAZ9KQ]...........................................................................................................................1751 Failure Code [DAZQKR]...........................................................................................................................1752 Failure Code [DB2QKR]...........................................................................................................................1756 Failure Code [DB2RKR]...........................................................................................................................1762 Failure Code [DD1ALD]...........................................................................................................................1767 Failure Code [DDAAL6]...........................................................................................................................1769 Failure Code [DDB2L4]...........................................................................................................................1771 Failure Code [DDB6L4]...........................................................................................................................1773 Failure Code [DDD7KA]...........................................................................................................................1775 Failure Code [DDD7KY]...........................................................................................................................1777 Failure Code [DDK3KA]...........................................................................................................................1779 Failure Code [DDK3KB]...........................................................................................................................1782 Failure Code [DDK6KA]...........................................................................................................................1785 Failure Code [DDK6KB]...........................................................................................................................1788 Failure Code [DDNRLD] (Applicable Machine: 85001 to 87648)......................................................................................1791 Failure Code [DDNRLD] (Applicable Machine: 87649 and Up)........................................................................................1793 Failure Code [DF10KA]...........................................................................................................................1795 Failure Code [DF10KB]...........................................................................................................................1798 Failure Code [DGH1KX]...........................................................................................................................1801 Failure Code [DGR2KB]...........................................................................................................................1803 Failure Code [DGR2KZ]...........................................................................................................................1805 Failure Code [DHA4KA]...........................................................................................................................1807 Failure Code [DHHBKA]...........................................................................................................................1809 Failure Code [DHHBKY]...........................................................................................................................1811 Failure Code [DHHCKA]...........................................................................................................................1813 Failure Code [DHHCKY]...........................................................................................................................1815 Failure Code [DHPCKA]...........................................................................................................................1817 Failure Code [DHPCKY]...........................................................................................................................1819 Failure Code [DHPEKA]...........................................................................................................................1821 Failure Code [DHPEKY]...........................................................................................................................1823 Failure Code [DHS8KA]...........................................................................................................................1825 Failure Code [DHS8KY]...........................................................................................................................1827 Failure Code [DHS9KA]...........................................................................................................................1829 Failure Code [DHS9KY]...........................................................................................................................1831 Failure Code [DHSDKA]...........................................................................................................................1833 Failure Code [DHSDKY]...........................................................................................................................1835 Failure Code [DHSNKA]...........................................................................................................................1837 Failure Code [DHSNKY]...........................................................................................................................1839 Failure Code [DHT8ZG]...........................................................................................................................1841 Failure Code [DHTCL6]...........................................................................................................................1842 Failure Code [DJF1KA]...........................................................................................................................1844 Failure Code [DK55KA]...........................................................................................................................1845 Failure Code [DK55KY]...........................................................................................................................1847 Failure Code [DK55L5]...........................................................................................................................1849 Failure Code [DK5DKA] (Applicable Machine: 85001 to 87648)......................................................................................1850 Failure Code [DK5DKA] (Applicable Machine: 87649 and Up)........................................................................................1853 Failure Code [DK5DKY] (Applicable Machine: 85001 to 87648)......................................................................................1856 Failure Code [DK5DKY] (Applicable Machine: 87649 and Up)........................................................................................1859 Failure Code [DK5DL8] (Applicable Machine: 85001 to 87648)......................................................................................1862 Failure Code [DK5DL8] (Applicable Machine: 87649 and Up)........................................................................................1866 Failure Code [DK5EKA] (Applicable Machine: 85001 to 87648)......................................................................................1870 Failure Code [DK5EKA] (Applicable Machine: 87649 and Up)........................................................................................1873 Failure Code [DK5EKY] (Applicable Machine: 85001 to 87648)......................................................................................1876 Failure Code [DK5EKY] (Applicable Machine: 87649 and Up)........................................................................................1879 Failure Code [DK70KA]...........................................................................................................................1882 Failure Code [DK70KY]...........................................................................................................................1884 Failure Code [DKA0KA]...........................................................................................................................1886 Failure Code [DKA0KY]...........................................................................................................................1889 Failure Code [DKA0L0]...........................................................................................................................1891 Failure Code [DLM3KA]...........................................................................................................................1893 Failure Code [DLM3LC]...........................................................................................................................1894 Failure Code [DLT3KX] (Applicable Machine: 85001 to 87648)......................................................................................1896 Failure Code [DLT3KX] (Applicable Machine: 87649 and Up)........................................................................................1898 Failure Code [DLT4KX] (Applicable Machine: 85001 to 87648)......................................................................................1900 Failure Code [DLT4KX] (Applicable Machine: 87649 and Up)........................................................................................1902 Failure Code [DLT4L0]...........................................................................................................................1904 Failure Code [DLT4LC] (Applicable Machine: 85001 to 87648)......................................................................................1905 Failure Code [DLT4LC] (Applicable Machine: 87649 and Up)........................................................................................1907 Failure Code [DPQ1KR]...........................................................................................................................1909 Failure Code [DPQ2KR]...........................................................................................................................1912 Failure Code [DPQ3KR]...........................................................................................................................1915 Failure Code [DSJ0KR]...........................................................................................................................1919 Failure Code [DT22KB] (Applicable Machine: 85001 to 87648)......................................................................................1924 Failure Code [DT22KB] (Applicable Machine: 87649 and Up)........................................................................................1926 Failure Code [DV00KB]...........................................................................................................................1928 Failure Code [DW26KA]...........................................................................................................................1929 Failure Code [DW26KB]...........................................................................................................................1931 Failure Code [DW26KY]...........................................................................................................................1933 Failure Code [DW4BKA] (Applicable Machine: 85001 to 87648)......................................................................................1935 Failure Code [DW4BKA] (Applicable Machine: 87649 and Up)........................................................................................1937 Failure Code [DW4BKB] (Applicable Machine: 85001 to 87648)......................................................................................1939 Failure Code [DW4BKB] (Applicable Machine: 87649 and Up)........................................................................................1941 Failure Code [DW4BKY] (Applicable Machine: 85001 to 87648)......................................................................................1943 Failure Code [DW4BKY] (Applicable Machine: 87649 and Up)........................................................................................1944 Failure Code [DW4RKA]...........................................................................................................................1946 Failure Code [DW4RKB]...........................................................................................................................1948 Failure Code [DW4RKY]...........................................................................................................................1950 Failure Code [DWM1KA] (Applicable Machine: 85001 to 87648)......................................................................................1952 Failure Code [DWM1KA] (Applicable Machine: 87649 and Up)........................................................................................1953 Failure Code [DWM1KB] (Applicable Machine: 85001 to 87648)......................................................................................1955 Failure Code [DWM1KB] (Applicable Machine: 87649 and Up)........................................................................................1957 Failure Code [DWM1KY] (Applicable Machine: 85001 to 87648)......................................................................................1959 Failure Code [DWM1KY] (Applicable Machine: 87649 and Up)........................................................................................1960 Failure Code [DWN6KA]...........................................................................................................................1962 Failure Code [DWN6KB]...........................................................................................................................1964 Failure Code [DWN6KY]...........................................................................................................................1966 Failure Code [DWN8KA]...........................................................................................................................1967 Failure Code [DWN8KB]...........................................................................................................................1968 Failure Code [DWN8KY]...........................................................................................................................1969 Failure Code [DX19KA]...........................................................................................................................1970 Failure Code [DX19KB]...........................................................................................................................1972 Failure Code [DX19KY]...........................................................................................................................1974 Failure Code [DX20KA]...........................................................................................................................1976 Failure Code [DX20KB]...........................................................................................................................1978 Failure Code [DX20KY]...........................................................................................................................1980 Failure Code [DXAWKA]...........................................................................................................................1981 Failure Code [DXAWKB]...........................................................................................................................1984 Failure Code [DXAWKY]...........................................................................................................................1987 Failure Code [DXH7KA]...........................................................................................................................1990 Failure Code [DXH7KB]...........................................................................................................................1992 Failure Code [DXH7KY]...........................................................................................................................1994 Failure Code [DXH8KA]...........................................................................................................................1996 Failure Code [DXH8KB]...........................................................................................................................1998 Failure Code [DXH8KY]...........................................................................................................................2000 Failure Code [DXHJKA]...........................................................................................................................2002 Failure Code [DXHJKB]...........................................................................................................................2004 Failure Code [DXHJKY]...........................................................................................................................2006 Failure Code [DXHKKA]...........................................................................................................................2007 Failure Code [DXHKKB]...........................................................................................................................2009 Failure Code [DXHKKY]...........................................................................................................................2011 Failure Code [F313KA]...........................................................................................................................2012 Failure Code [F313KB]...........................................................................................................................2014 Failure Code [F314KA]...........................................................................................................................2015 Failure Code [F314KB]...........................................................................................................................2017 Failure Code [F315KB]...........................................................................................................................2019 Failure Code [F315KY]...........................................................................................................................2021 Failure Code [F316KB]...........................................................................................................................2023 Failure Code [F316KY]...........................................................................................................................2025 Failure Code [F318KB]...........................................................................................................................2027 Failure Code [F318KY]...........................................................................................................................2029 Failure Code [F31AKB]...........................................................................................................................2030 Failure Code [F31AKY]...........................................................................................................................2032 Failure Code [F31BKB]...........................................................................................................................2034 Failure Code [F31BKY]...........................................................................................................................2036 Failure Code [F31CKB]...........................................................................................................................2038 Failure Code [F31CKY]...........................................................................................................................2040 Failure Code [F31DKB]...........................................................................................................................2042 Failure Code [F31DKY]...........................................................................................................................2044 Failure Code [F31EKB]...........................................................................................................................2046 Failure Code [F31EKY]...........................................................................................................................2048 Failure Code [FS10ZE]...........................................................................................................................2050 Failure Code [H2K0KA]...........................................................................................................................2051 Failure Code [H2K0KY]...........................................................................................................................2053 Failure Code [J141N1]...........................................................................................................................2055 Failure Code [LA00L3]...........................................................................................................................2056 Failure Code [M100N1]...........................................................................................................................2057 Failure Code [M400N1]...........................................................................................................................2058 Troubleshooting of Electrical System (E-Mode).......................................................................................................2059 Engine Does Not Start (Engine Does Not Crank)...................................................................................................2059 Manual Preheating System Does Not Operate.......................................................................................................2067 Automatic Preheating System Does Not Operate....................................................................................................2070 While Preheating is in Operation, Preheating Monitor Does Not Come On...........................................................................2073 The LCD Unit, LED Unit, and Meter Unit of the Machine Monitor Show Nothing......................................................................2075 LCD Unit on Machine Monitor Shows Nothing.......................................................................................................2078 Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers)...........................................................2080 LCD Screen on Machine Monitor Does Not Show Correctly...........................................................................................2082 Meter Unit Display on Machine Monitor is Abnormal...............................................................................................2084 Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal....................................................................................2087 LED Unit Lamp on Machine Monitor is Abnormal....................................................................................................2090 Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly.............................................2092 Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate......................................................................2095 Switch Panel Buzzer of Machine Monitor is Abnormal..............................................................................................2098 Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally................................................................2101 DEF Level is Not Shown Correctly................................................................................................................2102 Rearview Monitor Does Not Come On or Backlight Flickers.........................................................................................2105 Rearview Monitor Images are Not Shown Clearly...................................................................................................2108 Rearview Monitor Brightness Cannot be Adjusted..................................................................................................2112 Night Mode Lamp of Rearview Monitor is Abnormal.................................................................................................2116 Air Cleaner Clogging Indicator Lamp Does Not Come On............................................................................................2118 Radiator Coolant Level Caution Lamp Does Not Come On............................................................................................2120 Parking Brake Indicator Lamp Does Not Light When Parking Brake is Set to ON (Parking) Position..................................................2121 Brake Oil Pressure Caution Lamp Does Not Come On When Front Brake Accumulator Oil Pressure is Low...............................................2125 Brake Oil Pressure Caution Lamp Does Not Come On When Rear Brake Accumulator Oil Pressure is Low................................................2126 Indication of HST Oil Temperature Gauge Does Not Increase, or HST Oil Temperature Caution Lamp Does Not Come On.................................2127 When the Inching Pedal is Pushed, Inching Function Does Not Work or While the Pedal is Not Pushed, Inching Function Operates....................2128 Fuel Gauge Does Not Show Normally...............................................................................................................2130 Seatbelt Caution Lamp Does Not Show Normally....................................................................................................2132 Alarm Buzzer Does Not Operate...................................................................................................................2133 Alarm Buzzer Does Not Stop......................................................................................................................2134 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....2135 Setting Does Not Change While You Operate the Traction Control Switch...........................................................................2138 The Remote Positioner Does Not Work or Cannot be Released.......................................................................................2140 The Bucket Positioner Does Not Work or Cannot be Released.......................................................................................2142 Parking Brake Does Not Operate Even If It is Applied, or the Brake Drags in Forward or Reverse Travel When Parking Brake is Released............2145 Directional Selector (FNR) Switch Mode is Not Selected or Not Released..........................................................................2149 PZ Auto Tilt-in Does Not Work...................................................................................................................2151 PZ Auto Tilt-in Does Not Work (Applicable Machine: 85001 to 87648)..........................................................................2152 PZ Auto Tilt-in Does Not Work (Applicable Machine: 87649 and Up)............................................................................2155 Traction Level Does Not Show MAX When Max. Traction Switch is Turned on.........................................................................2158 ECSS Function Cannot be Selected or Cannot be Released..........................................................................................2160 ECSS Function Cannot be Selected or Cannot be Released (Applicable Machine: 85001 to 87648).................................................2161 ECSS Function Cannot be Selected or Cannot be Released (Applicable Machine: 87649 and Up)...................................................2163 Horn Does Not Sound.............................................................................................................................2165 Horn Does Not Stop..............................................................................................................................2168 Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On..........................................................................................2170 Clearance Lamp and Tail Lamp Do Not Come On or Go Out...........................................................................................2172 Clearance Lamp and Tail Lamp Do Not Come On or Go Out (for European Union and Turkey)...........................................................2176 High and Low Beams of Headlamp Do Not Come On or Go Out.........................................................................................2180 Both High and Low Beams of Headlamp Do Not Come On or Go Out (for European Union and Turkey)....................................................2184 Low Beam of Headlamp Does Not Come On or Go Out.................................................................................................2188 Low Beam of Headlamp Does Not Come on or Go off (for European Union and Turkey).................................................................2190 High Beam of Headlamp Does Not Come On or Go Out................................................................................................2192 High Beam of Headlamp Does Not Come On or Go Out (for European Union and Turkey)................................................................2194 Front Working Lamp Does Not Come On or Go Out...................................................................................................2196 Rear Working Lamp Does Not Come On or Go Out....................................................................................................2201 Turn Signal Lamp and Hazard Lamp Do Not Come On or Go Out.......................................................................................2205 Turn Signal Lamp Does Not Come On or Go Out.....................................................................................................2208 Turn Signal Lamps Do Not Come on or Go off (for European Union and Turkey)......................................................................2211 Hazard Lamp Does Not Come On or Go Out..........................................................................................................2214 Hazard Lamp Does Not Come On or Go Out (for European Union and Turkey)..........................................................................2218 Brake Lamp Does Not Come On or Stays Lit........................................................................................................2222 Brake Lamp Does Not Light or Stays Lighted (for European Union and Turkey)......................................................................2226 Backup Lamp Does Not Come On or Stays Lit.......................................................................................................2230 Backup Lamp Does Not Come On or Does Not Go Out (for European Union and Turkey).................................................................2234 Backup Buzzer Does Not Sound or Continues to Sound..............................................................................................2238 Front Wiper Does Not Operate....................................................................................................................2240 Rear Wiper Does Not Operate.....................................................................................................................2244 Window Washer Does Not Operate..................................................................................................................2247 KOMTRAX System Does Not Operate Correctly.......................................................................................................2250 Auto-Greasing Pump Display Shows [FCS]..........................................................................................................2251 Auto-Greasing Pump Display Shows [FLL]..........................................................................................................2252 Auto-Greasing System Does Not Operate or Stop...................................................................................................2253 Troubleshooting for Hydraulic and Mechanical Systems (H Mode).......................................................................................2254 Information Shown in Troubleshooting Table (H-Mode).............................................................................................2254 Failure Mode and Cause Table....................................................................................................................2255 Machine Can Not Move Forward or Reverse.........................................................................................................2269 Machine Can Not Travel FORWARD (Machine Travels REVERSE Normally)...............................................................................2272 Machine Can Not Travel REVERSE (Machine Travels FORWARD Normally)...............................................................................2273 Travel Speed of FORWARD Travel and REVERSE Travel is Slow, or Power is Low......................................................................2274 Forward Travel Speed is Slow or Power is Low (Machine Travels REVERSE Normally).................................................................2278 REVERSE Travel Speed is Slow or Power is Low (Machine Travels FORWARD Normally).................................................................2279 Engine Speed Drops Largely or Engine Stops......................................................................................................2280 Machine Does Not Turn...........................................................................................................................2282 Steering Wheel is Heavy to Operate..............................................................................................................2284 Machine Sways or Large Shocks are Made While Machine Turns......................................................................................2286 Machine Unintentionally Turns to One Side When Machine Travels..................................................................................2287 Wheel Brakes Do Not Operate or are Weak.........................................................................................................2288 Wheel Brakes are Not Released or Drag...........................................................................................................2290 Parking Brake Does Not Operate or is Weak.......................................................................................................2291 Parking Brake is Not Released or Drags..........................................................................................................2292 Boom Does Not Rise..............................................................................................................................2294 Boom Moves Slow or Lacks Lifting Force..........................................................................................................2297 Rising Boom Slows Down at Specified Height......................................................................................................2300 Lift Cylinders Can Not Hold Bucket on Ground....................................................................................................2301 Hydraulic Drift of Boom is Large................................................................................................................2303 Boom Moves Up and Down During Operation.........................................................................................................2304 Bucket Does Not Tilt Back.......................................................................................................................2305 Bucket Moves Slow or Lacks Tilt-Back Force......................................................................................................2308 Bucket Slows Down During Tilt Back Operation....................................................................................................2311 Bucket Cylinder Does Not Hold Bucket on Ground..................................................................................................2312 Hydraulic Drift of Bucket is Large..............................................................................................................2314 Bucket Tilts Back and Forth When You Carry Load (Work Equipment Valve is in Hold)...............................................................2315 Boom and Bucket Control Levers Do Not Move Smoothly and are Heavy to Move.......................................................................2316 Engine Speed Drops Largely or Engine Stops When You Operate Work Equipment......................................................................2317 Large Shocks are Made When Work Equipment Starts to Move and Stops..............................................................................2318 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves................................................................2320 ECSS Does Not Operate and Machine Pitches and Bounces...........................................................................................2321 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate).....................................................................................2322 Unusual Noise is Heard from Around Fan..........................................................................................................2325 Troubleshooting of Engine (S-Mode)..................................................................................................................2326 Information Shown in Troubleshooting Table (S-Mode).............................................................................................2326 Engine Does Not Crank When Starting Switch is Turned to Start Position..........................................................................2327 Engine Cranks but No Exhaust Smoke Comes Out....................................................................................................2328 Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start).........................................................2329 Engine Startability is Unsatisfactory...........................................................................................................2331 Engine Does Not Pick Up Smoothly................................................................................................................2333 Engine Stops During Operation...................................................................................................................2335 Engine Does Not Rotate Smoothly.................................................................................................................2337 Engine Lacks Output (or Lacks Power)............................................................................................................2338 KDPF Becomes Clogged in a Short Time............................................................................................................2340 Engine Oil Consumption is Excessive.............................................................................................................2342 Engine Oil Becomes Dirty Quickly................................................................................................................2343 Fuel Consumption is Excessive...................................................................................................................2344 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)...........................................................................2345 Engine Oil Pressure Drops.......................................................................................................................2346 Fuel Mixes Into Engine Oil......................................................................................................................2348 Water Mixes Into Engine Oil (Milky).............................................................................................................2349 Coolant Temperature Increases Too High (Overheat)...............................................................................................2350 Unusual Noise is Heard..........................................................................................................................2351 Vibration is Excessive..........................................................................................................................2352 Air Cannot be Bled from Fuel Circuit............................................................................................................2353 Active Regeneration is Done Frequently..........................................................................................................2354 Active Regeneration Continues Long..............................................................................................................2356 White Smoke is Exhausted During Active Regeneration.............................................................................................2357 DEF Consumption is Excessive....................................................................................................................2358 Foreign Materials Enter DEF (DEF Increases).....................................................................................................2360 Troubleshooting for Auto-Greasing System............................................................................................................2361 Outline of Failure Display......................................................................................................................2361 Troubleshooting for FCS.........................................................................................................................2362 Troubleshooting for Auto-Greasing Pump..........................................................................................................2363 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...........................................................................................................................2426 Remove and Install Supply Pump Assembly.........................................................................................................2426 How to Remove Supply Pump Assembly..........................................................................................................2427 How to Install Supply Pump Assembly.........................................................................................................2431 Remove and Install Injector Assembly............................................................................................................2438 How to Remove Injector Assembly.............................................................................................................2438 How to Install Injector Assembly............................................................................................................2446 Remove and Install Cylinder Head Assembly.......................................................................................................2456 How to Remove Cylinder Head Assembly........................................................................................................2457 How to Install Cylinder Head Assembly.......................................................................................................2468 Remove and Install EGR Valve Assembly...........................................................................................................2483 How to Remove EGR Valve Assembly............................................................................................................2483 How to Install EGR Valve Assembly...........................................................................................................2487 Remove and Install EGR Cooler Assembly..........................................................................................................2491 How to Remove EGR Cooler Assembly...........................................................................................................2491 How to Install EGR Cooler Assembly..........................................................................................................2495 Remove and Install Starter Assembly.............................................................................................................2499 How to Remove Starting Motor Assembly.......................................................................................................2499 How to Install Starting Motor Assembly......................................................................................................2501 Remove and Install Air Conditioner Compressor Belt..............................................................................................2505 How to Remove Air Conditioner Compressor Belt...............................................................................................2505 How to Install Air Conditioner Compressor Belt..............................................................................................2506 Remove and Install Alternator Belt..............................................................................................................2508 How to Remove Alternator Belt...............................................................................................................2508 How to Install Alternator Belt..............................................................................................................2511 Remove and Install Alternator Assembly..........................................................................................................2514 How to Remove Alternator Assembly...........................................................................................................2514 How to Install Alternator Assembly..........................................................................................................2517 Remove and Install Automatic Tensioner..........................................................................................................2521 How to Remove Automatic Tensioner...........................................................................................................2521 How to Install Automatic Tensioner..........................................................................................................2521 Remove and Install Radiator Assembly............................................................................................................2522 How to Remove Radiator Assembly.............................................................................................................2522 How to Install Radiator Assembly............................................................................................................2525 Remove and Install Cooling Fan and Fan Motor Assembly...........................................................................................2529 How to Remove Cooling Fan and Fan Motor Assembly............................................................................................2529 How to Install Cooling Fan and Fan Motor Assembly...........................................................................................2532 Remove and Install Hydraulic Oil Cooler Assembly................................................................................................2536 How to Remove Hydraulic Oil Cooler Assembly.................................................................................................2536 How to Install Hydraulic Oil Cooler Assembly................................................................................................2537 Remove and Install Aftercooler Assembly.........................................................................................................2539 How to Remove Aftercooler Assembly..........................................................................................................2539 How to Install Aftercooler Assembly.........................................................................................................2540 Remove and Install Engine Assembly..............................................................................................................2542 How to Remove Engine Assembly...............................................................................................................2543 How to Install Engine Assembly..............................................................................................................2562 Remove and Install Engine Front Oil Seal........................................................................................................2582 How to Remove Engine Front Oil Seal.........................................................................................................2582 How to Install Engine Front Oil Seal........................................................................................................2584 Remove and Install Engine Rear Oil Seal.........................................................................................................2587 How to Remove Engine Rear Oil Seal..........................................................................................................2587 How to Install Engine Rear Oil Seal.........................................................................................................2589 Remove and Install Engine Hood Assembly.........................................................................................................2593 How to Remove Engine Hood Assembly..........................................................................................................2593 How to Install Engine Hood Assembly.........................................................................................................2600 Remove and Install KDPF Assembly................................................................................................................2607 How to Remove KDPF Assembly.................................................................................................................2608 How to Install KDPF Assembly................................................................................................................2618 Disassemble and Assemble KDPF Assembly..........................................................................................................2631 How to Disassemble KDPF Assembly............................................................................................................2631 How to Assemble KDPF Assembly...............................................................................................................2636 Remove and Install KDPF and SCR Assembly........................................................................................................2641 How to Remove KDPF and SCR Assembly.........................................................................................................2642 How to Install KDPF and SCR Assembly........................................................................................................2652 Remove and Install Bellows Pipe Assembly........................................................................................................2667 How to Remove Bellows Pipe Assembly.........................................................................................................2667 How to Install Bellows Pipe Assembly........................................................................................................2670 Remove and Install Fuel Tank Assembly...........................................................................................................2675 How to Remove Fuel Tank Assembly............................................................................................................2675 How to Install Fuel Tank Assembly...........................................................................................................2679 Remove and Install DEF Tank Assembly............................................................................................................2683 How to Remove DEF Tank Assembly.............................................................................................................2684 How to Install DEF Tank Assembly............................................................................................................2690 Remove and Install DEF Tank Sensor Flange Assembly..............................................................................................2695 How to Remove DEF Tank Sensor Flange Assembly...............................................................................................2695 How to Install DEF Tank Sensor Flange Assembly..............................................................................................2697 Remove and Install DEF Tank Sensor..............................................................................................................2700 How to Remove DEF Tank Sensor...............................................................................................................2700 How to Install DEF Tank Sensor..............................................................................................................2701 Remove and Install DEF Tank Strainer............................................................................................................2708 How to Remove DEF Tank Strainer.............................................................................................................2708 How to Install DEF Tank Strainer............................................................................................................2709 Remove and Install SCR Assembly.................................................................................................................2710 How to Remove SCR Assembly..................................................................................................................2711 How to Install SCR Assembly.................................................................................................................2721 Remove and Install KCCV Assembly................................................................................................................2735 How to Remove KCCV Assembly.................................................................................................................2735 How to Install KCCV Assembly................................................................................................................2737 Remove and Install VGT Assembly.................................................................................................................2740 How to Remove VGT Assembly..................................................................................................................2740 How to Install VGT Assembly.................................................................................................................2747 Remove and Install DEF Mixing Tube..............................................................................................................2756 How to Remove DEF Mixing Tube...............................................................................................................2757 How to Install DEF Mixing Tube..............................................................................................................2762 Remove and Install DEF Injector.................................................................................................................2770 How to Remove DEF Injector..................................................................................................................2770 How to Install DEF Injector.................................................................................................................2773 Remove and Install DEF Pump.....................................................................................................................2778 How to Remove DEF Pump......................................................................................................................2778 How to Install DEF Pump.....................................................................................................................2780 Remove and Install DEF Hose.....................................................................................................................2783 How to Remove DEF Hose......................................................................................................................2783 How to Install DEF Hose.....................................................................................................................2791 Remove and Install Air Cleaner Assembly.........................................................................................................2799 How to Remove Air Cleaner Assembly..........................................................................................................2799 How to Install Air Cleaner Assembly.........................................................................................................2802 Remove and Install Air Conditioner Compressor Assembly..........................................................................................2805 How to Remove Air Conditioner Compressor Assembly...........................................................................................2806 How to Install Air Conditioner Compressor Assembly..........................................................................................2808 Remove and Install Air Conditioner Condenser Assembly...........................................................................................2810 How to Remove Air Conditioner Condenser Assembly............................................................................................2810 How to Install Air Conditioner Condenser Assembly...........................................................................................2812 Power Train.........................................................................................................................................2815 Remove and Install HST Pump Assembly............................................................................................................2815 How to Remove HST Pump Assembly.............................................................................................................2816 How to Install HST Pump Assembly............................................................................................................2822 Remove and Install HST Motor 1 Assembly.........................................................................................................2831 How to Remove HST Motor 1 Assembly..........................................................................................................2831 How to Install HST Motor 1 Assembly.........................................................................................................2834 Remove and Install HST Motor 2 Assembly.........................................................................................................2837 How to Remove HST Motor 2 Assembly..........................................................................................................2838 How to Install HST Motor 2 Assembly.........................................................................................................2846 Remove and Install Transfer Assembly............................................................................................................2856 How to Remove Transfer Assembly.............................................................................................................2857 How to Install Transfer Assembly............................................................................................................2861 Disassemble and Assemble Transfer Assembly......................................................................................................2868 How to Disassemble Transfer Assembly........................................................................................................2870 How to Assemble Transfer Assembly...........................................................................................................2890 Remove and Install Front Axle Assembly..........................................................................................................2915 How to Remove Front Axle Assembly...........................................................................................................2915 How to Install Front Axle Assembly..........................................................................................................2917 Remove and Install Rear Axle Assembly...........................................................................................................2920 How to Remove Rear Axle Assembly............................................................................................................2920 How to Install Rear Axle Assembly...........................................................................................................2924 Disassemble and Assemble Axle Housing Assembly..................................................................................................2928 How to Disassemble Axle Housing Assembly....................................................................................................2929 How to Assemble Axle Housing Assembly.......................................................................................................2937 Disassemble and Assemble Differential Assembly..................................................................................................2947 How to Disassemble Differential Assembly....................................................................................................2948 How to Assemble Differential Assembly.......................................................................................................2961 Undercarriage and Frame.............................................................................................................................2981 Remove and Install Center Hinge Pin.............................................................................................................2981 How to Remove Center Hinge Pin..............................................................................................................2982 How to Install Center Hinge Pin.............................................................................................................2988 Remove and Install Counterweight Assembly.......................................................................................................2999 How to Remove Counterweight Assembly........................................................................................................2999 How to Install Counterweight Assembly.......................................................................................................3005 Hydraulic System....................................................................................................................................3010 Remove and Install Hydraulic Tank Assembly......................................................................................................3010 How to Remove Hydraulic Tank Assembly.......................................................................................................3010 How to Install Hydraulic Tank Assembly......................................................................................................3021 Remove and Install Control Valve Assembly.......................................................................................................3031 How to Remove Control Valve Assembly........................................................................................................3031 How to Install Control Valve Assembly.......................................................................................................3037 Remove and Install Quick Coupler LS Pressure Rise Valve Assembly................................................................................3042 How to Remove Quick Coupler LS Pressure Rise Valve Assembly.................................................................................3042 How to Install Quick Coupler LS Pressure Rise Valve Assembly................................................................................3045 Disassemble and Assemble Work Equipment Cylinder Assembly.......................................................................................3048 How to Disassemble Work Equipment Cylinder Assembly.........................................................................................3049 How to Assemble Work Equipment Cylinder Assembly............................................................................................3053 Work Equipment......................................................................................................................................3061 Remove and Install Work Equipment Assembly......................................................................................................3061 How to Remove Work Equipment Assembly.......................................................................................................3062 How to Install Work Equipment Assembly......................................................................................................3066 CAB Related Parts...................................................................................................................................3077 Remove and Install Operator Cab and Floor Frame Assembly........................................................................................3077 How to Remove Operator Cab and Floor Frame Assembly.........................................................................................3078 How to Install Operator Cab and Floor Frame Assembly........................................................................................3086 Remove and Install Operator Cab Glass (Adhered Glass)...........................................................................................3094 How to Remove Operator Cab Glass (Adhered Glass)............................................................................................3094 How to Install Operator Cab Glass (Adhered Glass)...........................................................................................3095 Remove and Install Air Conditioner Unit Assembly................................................................................................3104 How to Remove Air Conditioner Unit Assembly.................................................................................................3104 How to Install Air Conditioner Unit Assembly................................................................................................3110 Remove and Install Operator Seat Assembly.......................................................................................................3117 How to Remove Operator Seat Assembly........................................................................................................3117 How to Install Operator Seat Assembly.......................................................................................................3117 How to Remove and Install Seat Belt.............................................................................................................3119 How to Remove Seat Belt.....................................................................................................................3119 How to Install Seatbelt.....................................................................................................................3119 Electrical System...................................................................................................................................3121 Remove and Install Engine Controller Assembly...................................................................................................3121 How to Remove Engine Controller Assembly....................................................................................................3121 How to Install Engine Controller Assembly...................................................................................................3126 Remove and Install HST Controller Assembly......................................................................................................3132 How to Remove HST Controller Assembly.......................................................................................................3132 How to Install HST Controller Assembly......................................................................................................3134 Remove and Install Air Conditioner Controller Assembly..........................................................................................3136 How to Remove Air Conditioner Controller Assembly...........................................................................................3136 How to Install Air Conditioner Controller Assembly..........................................................................................3137 Remove and Install Monitor Controller Assembly..................................................................................................3139 How to Remove Monitor Controller Assembly...................................................................................................3139 How to Install Monitor Controller Assembly..................................................................................................3142 Remove and Install Machine Monitor Assembly.....................................................................................................3144 How to Remove Machine Monitor Assembly......................................................................................................3144 How to Install Machine Monitor Assembly.....................................................................................................3147 Remove and Install Mass Air Flow and Temperature Sensor.........................................................................................3150 How to Remove Mass Air Flow and Temperature Sensor..........................................................................................3150 How to Install Mass Air Flow and Temperature Sensor.........................................................................................3151 Remove and Install KCCV Crankcase Pressure Sensor...............................................................................................3152 How to Remove KCCV Crankcase Pressure Sensor................................................................................................3152 How to Install KCCV Crankcase Pressure Sensor...............................................................................................3153 Remove and Install KDPF Temperature Sensor......................................................................................................3155 How to Remove KDPF Temperature Sensor.......................................................................................................3155 How to Install KDPF Temperature Sensor......................................................................................................3157 Remove and Install KDPF Differential Pressure Sensor............................................................................................3160 How to Remove KDPF Differential Pressure Sensor.............................................................................................3160 How to Install KDPF Differential Pressure Sensor............................................................................................3163 Remove and Install SCR Temperature Sensor.......................................................................................................3165 How to Remove SCR Temperature Sensor........................................................................................................3165 How to Install SCR Temperature Sensor.......................................................................................................3166 Remove and Install Ammonia Sensor...............................................................................................................3168 How to Remove Ammonia Sensor................................................................................................................3168 How to Install Ammonia Sensor...............................................................................................................3170 Remove and Install SCR Outlet NOx Sensor........................................................................................................3173 How to Remove SCR Outlet NOx Sensor.........................................................................................................3173 How to Install SCR Outlet NOx Sensor........................................................................................................3176 Remove and Install Gateway Function Controller Assembly.........................................................................................3179 How to Remove Gateway Function Controller Assembly..........................................................................................3179 How to Install Gateway Function Controller Assembly.........................................................................................3180 Remove and Install Communication Terminal.......................................................................................................3181 How to Remove Communication Terminal........................................................................................................3181 How to Install Communication Terminal.......................................................................................................3183 60 Maintenance Standard.................................................................................................................................3187 Table of Contents...................................................................................................................................3188 Abbreviation List...................................................................................................................................3189 Engine and Cooling System...........................................................................................................................3195 Maintenance Standard for Engine Mount...........................................................................................................3195 Maintenance Standard for Damper.................................................................................................................3196 Maintenance Standard for Cooling Fan Motor......................................................................................................3198 Power Train.........................................................................................................................................3200 Maintenance Standard for Drive Shaft............................................................................................................3200 Maintenance Standard for Transfer...............................................................................................................3201 Maintenance Standard for Transfer Mount.........................................................................................................3209 Maintenance Standard for Front Axle.............................................................................................................3210 Maintenance Standard for Rear Axle..............................................................................................................3211 Maintenance Standard for Front Torque Proportioning Differential................................................................................3212 Maintenance Standard for Rear Torque Proportioning Differential.................................................................................3214 Maintenance Standard for Limited Slip Differential..............................................................................................3216 Maintenance Standard for Final Drive............................................................................................................3218 Steering System.....................................................................................................................................3220 Maintenance Standard for Steering Column........................................................................................................3220 Maintenance Standard for Priority Valve.........................................................................................................3221 Maintenance Standard for Steering Cylinder......................................................................................................3222 Maintenance Standard for Secondary Steering Valve...............................................................................................3225 Brake System........................................................................................................................................3226 Maintenance Standard for Brake Circuit Accumulator Charge Valve.................................................................................3226 Maintenance Standard for Slack Adjuster.........................................................................................................3227 Maintenance Standard for Front Brake............................................................................................................3228 Maintenance Standard for Rear Brake.............................................................................................................3229 Maintenance Standard for Parking Brake..........................................................................................................3230 Maintenance Standard for Parking Brake Solenoid Valve...........................................................................................3232 Undercarriage and Frame.............................................................................................................................3233 Maintenance Standard for Frame, Axle Mount and Center Hinge Pin.................................................................................3233 Hydraulic System....................................................................................................................................3238 Maintenance Standard for Hydraulic Tank.........................................................................................................3238 Maintenance Standard for Brake and Cooling Fan Pump and Transfer Lubrication Pump...............................................................3239 Maintenance Standard for Steering and Work Equipment Pump.......................................................................................3240 Maintenance Standard for Servo Valve of Steering and Work Equipment Pump....................................................................3243 Maintenance Standard for Control Valve..........................................................................................................3244 Maintenance Standard for Self-Pressure Reducing Valve...........................................................................................3256 Maintenance Standard for Multifunction Mono-Lever PPC Valve.....................................................................................3258 Maintenance Standard for Work Equipment Lock Solenoid Valve.....................................................................................3260 Work Equipment......................................................................................................................................3261 Maintenance Standard for Work Equipment Linkage.................................................................................................3261 Maintenance Standard for Bucket.................................................................................................................3265 Maintenance Standard for Lift Cylinder..........................................................................................................3267 Maintenance Standard for Bucket Cylinder........................................................................................................3268 CAB Related Parts...................................................................................................................................3269 Maintenance Standard for CAB Mount..............................................................................................................3269 80 Appendix.............................................................................................................................................3271 Table of Contents...................................................................................................................................3272 Precautions Before Work.............................................................................................................................3274 Abbreviation List...................................................................................................................................3275 Air Conditioner System..............................................................................................................................3281 Precautions for Refrigerant.....................................................................................................................3281 Air Conditioner Component.......................................................................................................................3282 Specifications of Air Conditioner...............................................................................................................3284 Structure and Function of Refrigeration Cycle...................................................................................................3285 Outline of Refrigeration Cycle..................................................................................................................3286 Component Parts of Air Conditioner System...........................................................................................................3288 Air Conditioner Unit............................................................................................................................3288 Configuration Diagram of Air Conditioner Unit...............................................................................................3288 Function of Air Conditioner Unit............................................................................................................3289 Component Parts of Air Conditioner Unit.........................................................................................................3290 Function of Evaporator as Air Conditioner Unit Component....................................................................................3290 Function of Inside Air Temperature Sensor as Air Conditioner Unit Component.................................................................3290 Function of Blower Amplifier as Air Conditioner Unit Component..............................................................................3291 Function of Blower OFF Relay as Air Conditioner Unit Component..............................................................................3291 Function of Compressor Clutch Relay as Air Conditioner Unit Component.......................................................................3291 Function of Heater Core as Air Conditioner Unit Component...................................................................................3291 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component.................................................................3291 Function of Servo Motor as Air Conditioner Unit Component...................................................................................3291 Function of Expansion Valve as Air Conditioner Unit Component...............................................................................3292 Function of Dual Pressure Switch............................................................................................................3292 Air Conditioner Controller......................................................................................................................3293 Structure of Air Conditioner Controller.....................................................................................................3293 Compressor......................................................................................................................................3294 Structure of Compressor.....................................................................................................................3294 Specifications of Compressor................................................................................................................3294 Function of Compressor......................................................................................................................3294 Condenser.......................................................................................................................................3295 Structure of Condenser......................................................................................................................3295 Specifications of Condenser.................................................................................................................3295 Function of Condenser.......................................................................................................................3295 Receiver Drier..................................................................................................................................3296 Structure of Receiver Dryer.................................................................................................................3296 Specifications of Receiver Dryer............................................................................................................3296 Function of Receiver Dryer..................................................................................................................3296 Air Conditioner Related Sensors.................................................................................................................3297 Function of Sunlight Sensor.................................................................................................................3297 Function of Outside Air Temperature Sensor..................................................................................................3297 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner.........................................................................3298 Circuit Diagram and Configuration of Connector Pins of Air Conditioner..............................................................................3300 System Diagram of Air Conditioner...................................................................................................................3303 Input and Output Signals of Air Conditioner Controller..........................................................................................3304 Function of Air Conditioner Controller......................................................................................................3305 Locations of Air Conditioner Parts and Layout of Connectors.........................................................................................3306 Examine Air Conditioner with Self-Diagnosis Function................................................................................................3312 Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor.............................................................3313 Examine Temperature Control Function................................................................................................................3314 How to Examine Temperature Control Function.....................................................................................................3314 Examine Vent (Mode) Changeover......................................................................................................................3316 How to Examine Vent (Mode) Changeover...........................................................................................................3316 Examine Fresh/Recirc Air Changeover.................................................................................................................3318 How to Examine Fresh/Recirc Air Changeover......................................................................................................3318 Examine Evaporator Temperature Sensor...............................................................................................................3320 Examine Relay.......................................................................................................................................3322 How to Examine Relay............................................................................................................................3322 Air Conditioner Troubleshooting Chart 1.............................................................................................................3324 Air Conditioner Troubleshooting Chart 2.............................................................................................................3325 Failure Code [879AKA]...............................................................................................................................3328 Failure Code [879AKB]...............................................................................................................................3330 Failure Code [879BKA]...............................................................................................................................3332 Failure Code [879BKB]...............................................................................................................................3334 Failure Code [879CKA]...............................................................................................................................3336 Failure Code [879CKB]...............................................................................................................................3338 Failure Code [879DKZ]...............................................................................................................................3340 Failure Code [879EMC]...............................................................................................................................3342 Failure Code [879FMC]...............................................................................................................................3343 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)..........................................................................3344 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)...........................................................................3347 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)..................................................................3350 Troubleshooting for Fresh/Recirc Air Changeover.....................................................................................................3354 Troubleshooting by Gauge Pressure...................................................................................................................3356 Connect Service Tool................................................................................................................................3359 How to Connect Service Tool.....................................................................................................................3360 Precautions for Disconnection and Connection of Air Conditioner Piping..............................................................................3361 Handle Compressor Oil...............................................................................................................................3363 90 Circuit Diagrams.....................................................................................................................................3365 Table of Contents...................................................................................................................................3366 Abbreviation List...................................................................................................................................3368 Hydraulic Circuit Diagram...........................................................................................................................3374 Symbols Used in Hydraulic Circuit Diagram.......................................................................................................3374 Hydraulic Circuit Diagram (1/2).................................................................................................................3379 Hydraulic Circuit Diagram (2/2).................................................................................................................3381 Hydraulic Auto-Greasing Diagram.................................................................................................................3383 Electrical Circuit Diagram..........................................................................................................................3385 Symbols Used in Electric Circuit Diagram........................................................................................................3385 Electrical Circuit Diagram of Machine (Applicable Machine: 86025 to 87648) (1/8)................................................................3389 Electrical Circuit Diagram of Machine (Applicable Machine: 86025 to 87648) (2/8)................................................................3391 Electrical Circuit Diagram of Machine (Applicable Machine: 86025 to 87648) (3/8)................................................................3393 Electrical Circuit Diagram of Machine (Applicable Machine: 86025 to 87648) (4/8)................................................................3395 Electrical Circuit Diagram of Machine (Applicable Machine: 86025 to 87648) (5/8)................................................................3397 Electrical Circuit Diagram of Machine (Applicable Machine: 86025 to 87648) (6/8)................................................................3399 Electrical Circuit Diagram of Machine (Applicable Machine: 86025 to 87648) (7/8)................................................................3401 Electrical Circuit Diagram of Machine (Applicable Machine: 86025 to 87648) (8/8)................................................................3403 Electrical Circuit Diagram of Machine (Applicable Machine: 87649 and Up) (1/8)..................................................................3405 Electrical Circuit Diagram of Machine (Applicable Machine: 87649 and Up) (2/8)..................................................................3407 Electrical Circuit Diagram of Machine (Applicable Machine: 87649 and Up) (3/8)..................................................................3409 Electrical Circuit Diagram of Machine (Applicable Machine: 87649 and Up) (4/8)..................................................................3411 Electrical Circuit Diagram of Machine (Applicable Machine: 87649 and Up) (5/8)..................................................................3413 Electrical Circuit Diagram of Machine (Applicable Machine: 87649 and Up) (6/8)..................................................................3415 Electrical Circuit Diagram of Machine (Applicable Machine: 87649 and Up) (7/8)..................................................................3417 Electrical Circuit Diagram of Machine (Applicable Machine: 87649 and Up) (8/8)..................................................................3419 Electrical Circuit Diagram of Machine (Machine with Collision Detection System) (Applicable Machine: 87649 and Up) (1/8)........................3421 Electrical Circuit Diagram of Machine (Machine with Collision Detection System) (Applicable Machine: 87649 and Up) (2/8)........................3423 Electrical Circuit Diagram of Machine (Machine with Collision Detection System) (Applicable Machine: 87649 and Up) (3/8)........................3425 Electrical Circuit Diagram of Machine (Machine with Collision Detection System) (Applicable Machine: 87649 and Up) (4/8)........................3427 Electrical Circuit Diagram of Machine (Machine with Collision Detection System) (Applicable Machine: 87649 and Up) (5/8)........................3429 Electrical Circuit Diagram of Machine (Machine with Collision Detection System) (Applicable Machine: 87649 and Up) (6/8)........................3431 Electrical Circuit Diagram of Machine (Machine with Collision Detection System) (Applicable Machine: 87649 and Up) (7/8)........................3433 Electrical Circuit Diagram of Machine (Machine with Collision Detection System) (Applicable Machine: 87649 and Up) (8/8)........................3435 Electrical Circuit Diagram of Floor (Applicable Machine: 86025 to 87648) (1/10).................................................................3437 Electrical Circuit Diagram of Floor (Applicable Machine: 86025 to 87648) (2/10).................................................................3439 Electrical Circuit Diagram of Floor (Applicable Machine: 86025 to 87648) (3/10).................................................................3441 Electrical Circuit Diagram of Floor (Applicable Machine: 86025 to 87648) (4/10).................................................................3443 Electrical Circuit Diagram of Floor (Applicable Machine: 86025 to 87648) (5/10).................................................................3445 Electrical Circuit Diagram of Floor (Applicable Machine: 86025 to 87648) (6/10).................................................................3447 Electrical Circuit Diagram of Floor (Applicable Machine: 86025 to 87648) (7/10).................................................................3449 Electrical Circuit Diagram of Floor (Applicable Machine: 86025 to 87648) (8/10).................................................................3451 Electrical Circuit Diagram of Floor (Applicable Machine: 86025 to 87648) (9/10).................................................................3453 Electrical Circuit Diagram of Floor (Applicable Machine: 86025 to 87648) (10/10)................................................................3455 Electrical Circuit Diagram of Floor (Applicable Machine: 87649 and Up) (1/11)...................................................................3457 Electrical Circuit Diagram of Floor (Applicable Machine: 87649 and Up) (2/11)...................................................................3459 Electrical Circuit Diagram of Floor (Applicable Machine: 87649 and Up) (3/11)...................................................................3461 Electrical Circuit Diagram of Floor (Applicable Machine: 87649 and Up) (4/11)...................................................................3463 Electrical Circuit Diagram of Floor (Applicable Machine: 87649 and Up) (5/11)...................................................................3465 Electrical Circuit Diagram of Floor (Applicable Machine: 87649 and Up) (6/11)...................................................................3467 Electrical Circuit Diagram of Floor (Applicable Machine: 87649 and Up) (7/11)...................................................................3469 Electrical Circuit Diagram of Floor (Applicable Machine: 87649 and Up) (8/11)...................................................................3471 Electrical Circuit Diagram of Floor (Applicable Machine: 87649 and Up) (9/11)...................................................................3473 Electrical Circuit Diagram of Floor (Applicable Machine: 87649 and Up) (10/11)..................................................................3475 Electrical Circuit Diagram of Floor (Applicable Machine: 87649 and Up) (11/11)..................................................................3477 Index....................................................................................................................................................3479
DESCRIPTION:
KOMATSU WA320-8E0 WHEEL LOADER SHOP MANUAL SEN06792-06 – 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
