Komatsu WA480-8 Wheel Loader Shop Manual SEN06663-01 PDF

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Komatsu WA480-8 Wheel Loader Shop Manual SEN06663-01 – PDF DOWNLOAD

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Komatsu WA480-8 Wheel Loader Shop Manual SEN06663-01 – PDF DOWNLOAD

Language : English
Pages : 3721
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Komatsu WA480-8 Wheel Loader Shop Manual SEN06663-01 – PDF DOWNLOAD 

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 25
FOREWORD, SAFETY, BASIC INFORMATION 31
HOW TO READ THE SHOP MANUAL 31
SAFETY NOTICE FOR OPERATION 33
PRECAUTIONS TO PREVENT FIRE 41
ACTIONS IF FIRE OCCURS 43
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 44
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 45
PRECAUTIONS FOR DEF 46
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 46
PRECAUTIONS FOR ADDING 46
PRECAUTIONS FOR STORING 46
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 46
THE OTHER PRECAUTIONS 46
STORE AdBlue/DEF 47
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 48
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 51
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 58
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 60
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 61
PRACTICAL USE OF KOMTRAX 62
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 63
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 63
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 64
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 65
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 67
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 71
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 74
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 75
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 77
HOW TO READ ELECTRICAL WIRE CODE 78
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 82
STANDARD TIGHTENING TORQUE TABLE 85
CONVERSION TABLE 92
01 SPECIFICATIONS 97
CONTENTS 98
ABBREVIATION LIST 99
SPECIFICATIONS 105
SPECIFICATION DRAWING 105
SPECIFICATION DRAWING: WA480-8 105
SPECIFICATIONS 107
SPECIFICATIONS: WA480-8 107
WEIGHT TABLE 112
WEIGHT TABLE:WA480-8 112
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) 114
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 114
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION) 116
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 116
10 STRUCTURE AND FUNCTION 119
CONTENTS 120
ABBREVIATION LIST 125
UREA SCR SYSTEM 131
LAYOUT DRAWING OF UREA SCR SYSTEM 131
UREA SCR SYSTEM DIAGRAM 133
FUNCTION OF UREA SCR SYSTEM 134
FUNCTION OF AdBlue/DEF SYSTEM 134
INDUCEMENT STRATEGY 137
COMPONENT PARTS OF UREA SCR SYSTEM 151
AdBlue/DEF MIXING TUBE 151
SCR ASSEMBLY 152
AdBlue/DEF TANK 154
AdBlue/DEF PUMP 156
AdBlue/DEF INJECTOR 157
AdBlue/DEF HOSE 158
AdBlue/DEF TANK HEATING VALVE 159
BOOT-UP SYSTEM 160
LAYOUT DRAWING OF BOOT-UP SYSTEM 160
SYSTEM OPERATING LAMP SYSTEM 162
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 162
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 162
BATTERY DISCONNECT SWITCH 163
FUNCTION OF BATTERY DISCONNECT SWITCH 163
PREHEATING SYSTEM 164
PREHEATING SYSTEM DIAGRAM 164
FUNCTION OF AUTOMATIC PREHEATING SYSTEM 164
OPERATION OF AUTOMATIC PREHEATING SYSTEM 164
FUNCTION OF MANUAL PREHEATING SYSTEM 165
OPERATION OF MANUAL PREHEATING SYSTEM 165
ENGINE SYSTEM 166
LAYOUT DRAWING OF ENGINE SYSTEM 166
FUNCTION OF ENGINE SYSTEM 167
ENGINE CONTROL SYSTEM 168
ENGINE CONTROL SYSTEM DIAGRAM 168
FUNCTION OF ENGINE CONTROL SYSTEM 169
OPERATION OF ENGINE CONTROL SYSTEM 172
ENGINE POWER MODE SELECTOR SYSTEM 174
ENGINE POWER MODE SELECTOR SYSTEM DIAGRAM 174
FUNCTION OF ENGINE POWER MODE SELECTOR SYSTEM 174
OPERATION OF ENGINE POWER MODE SELECTOR SYSTEM 174
AUTOMATIC IDLE STOP SYSTEM 175
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 175
COMPONENT PARTS OF ENGINE SYSTEM 176
VGT 176
EGR SYSTEM 180
EGR VALVE 182
EGR COOLER 184
KCCV SYSTEM 185
KCCV VENTILATOR 187
KDPF 189
COOLING SYSTEM 193
LAYOUT DRAWING OF COOLING SYSTEM 193
SPECIFICATIONS OF COOLING SYSTEM 194
COOLING FAN CONTROL SYSTEM 195
COOLING FAN CONTROL SYSTEM DIAGRAM 195
FUNCTION OF COOLING FAN CONTROL SYSTEM 195
COMPONENT PARTS OF COOLING SYSTEM 200
BRAKE AND COOLING FAN PUMP 200
COOLING FAN MOTOR 208
CONTROL SYSTEM 214
LAYOUT DRAWING OF CONTROL SYSTEM 214
MACHINE MONITOR SYSTEM 216
MACHINE MONITOR SYSTEM DIAGRAM 216
FUNCTION OF MACHINE MONITOR SYSTEM 216
REARVIEW MONITOR SYSTEM 218
REARVIEW MONITOR SYSTEM DIAGRAM 218
FUNCTION OF REARVIEW MONITOR SYSTEM 218
KOMTRAX SYSTEM 219
KOMTRAX SYSTEM DIAGRAM 219
FUNCTION OF KOMTRAX SYSTEM 219
LOAD METER SYSTEM 220
LOAD METER SYSTEM DIAGRAM 220
FUNCTION OF LOAD METER SYSTEM 220
COMPONENT PARTS OF CONTROL SYSTEM 226
MACHINE MONITOR 226
SWITCH PANEL 246
REARVIEW MONITOR 247
REARVIEW CAMERA 249
KOMTRAX TERMINAL 250
TRANSMISSION CONTROLLER 252
WORK EQUIPMENT CONTROLLER 256
MONITOR CONTROLLER 260
CAN TERMINATING RESISTOR 265
ENGINE CONTROLLER 266
ACCELERATOR PEDAL 273
HYDRAULIC SYSTEM 275
LAYOUT DRAWING OF HYDRAULIC SYSTEM 275
CLSS 276
STRUCTURE OF CLSS 276
FUNCTION OF CLSS 277
WORK EQUIPMENT PUMP AND STEERING PUMP CONTROL SYSTEM 279
SWASH PLATE CONTROL FUNCTION OF WORK EQUIPMENT PUMP AND STEERING PUMP 279
PICKUP ASSISTANCE CONTROL FUNCTION WHEN ENGINE SPEED IS LOW 279
OVERHEAT PREVENTION FUNCTION OF WORK EQUIPMENT CIRCUIT 279
COMPONENT PARTS OF HYDRAULIC SYSTEM 280
HYDRAULIC TANK 280
WORK EQUIPMENT PUMP 283
STEERING PUMP 301
POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP 313
CONTROL VALVE 314
POWER TRAIN SYSTEM 348
LAYOUT DRAWING OF POWER TRAIN SYSTEM 348
OPERATION OF POWER TRAIN SYSTEM 351
TRANSMISSION CONTROL SYSTEM 352
TRANSMISSION CONTROL SYSTEM DIAGRAM 352
TRANSMISSION GEAR SHIFT CONTROL SYSTEM 354
ELECTRIC MODULATION FUNCTION SYSTEM DIAGRAM 354
ELECTRIC MODULATION FUNCTION 355
DISPLAY FUNCTION OF GEAR SHIFT 355
AUTOMATIC GEAR SHIFT FUNCTION 355
SHIFT HOLD FUNCTION 356
KICKDOWN FUNCTION 356
AUTOMATIC KICKDOWN FUNCTION 357
TORQUE CONVERTER LOCKUP FUNCTION 357
HUNTING PREVENTION FUNCTION 358
ADJUSTING FUNCTION OF TRANSMISSION INITIAL LEARNING AND ECMV CURRENT 358
SHIFT POINT CHANGING FUNCTION 358
4TH GEAR SPEED LIMITATION FUNCTION 358
TRANSMISSION PROTECTION FUNCTION 360
PROTECTION FUNCTION WHEN TRAVEL DIRECTION IS CHANGED 360
SHIFT DOWN PROTECTION FUNCTION 360
ENGINE OVERRUN PREVENTION FUNCTION 361
MAXIMUM SPEED LIMITATION FUNCTION 361
NEUTRALIZER FUNCTION 361
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION 363
TRANSMISSION CUT-OFF FUNCTION 365
COMPONENT PARTS OF POWER TRAIN SYSTEM 367
DRIVE SHAFT 367
TORQUE CONVERTER 369
LOCKUP CLUTCH ECMV 372
TRANSMISSION 375
TRANSMISSION CONTROL VALVE 392
FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND CLUTCH ECMV 395
3RD AND 4TH CLUTCH ECMV 400
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 405
AXLE 407
CONVENTIONAL DIFFERENTIAL 409
LIMITED SLIP DIFFERENTIAL 412
FINAL DRIVE 417
AJSS KNOB 419
COMBINATION SWITCH 420
SHIFT HOLD SWITCH 424
KICKDOWN SWITCH 425
WORK EQUIPMENT SYSTEM 426
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 426
WORK EQUIPMENT SYSTEM DIAGRAM 428
WORK EQUIPMENT CONTROL SYSTEM 430
WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE 430
WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION 430
WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM 431
WORK EQUIPMENT LEVER OPERATION FUNCTION 432
BUCKET PRIORITY CONTROL FUNCTION 432
BOOM STOP MODULATION FUNCTION 432
WORK EQUIPMENT NEUTRAL LOCK SYSTEM 434
WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM 434
FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM 434
REMOTE POSITIONER SYSTEM 436
REMOTE BUCKET POSITIONER SYSTEM DIAGRAM 436
FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM 436
REMOTE BOOM POSITIONER SYSTEM DIAGRAM 437
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM 437
BUCKET POSITIONER AND BOOM POSITIONER 441
STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER 441
AUTO-DIGGING SYSTEM 442
AUTO-DIGGING SYSTEM DIAGRAM 442
FUNCTION OF AUTO-DIGGING SYSTEM 442
ECSS 444
ECSS DIAGRAM 444
FUNCTION OF ECSS 444
OPERATION OF ECSS 444
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 446
WORK EQUIPMENT LOCK SOLENOID VALVE 446
PILOT CIRCUIT ACCUMULATOR 447
ECSS CIRCUIT ACCUMULATOR 448
WORK EQUIPMENT ELECTRIC LEVER 450
MULTIFUNCTION MONO-LEVER 453
STEERING SYSTEM 454
LAYOUT DRAWING OF STEERING SYSTEM 454
SECONDARY STEERING SYSTEM 457
SECONDARY STEERING SYSTEM DIAGRAM 457
FUNCTION OF SECONDARY STEERING SYSTEM 457
AJSS 459
LAYOUT DRAWING OF AJSS 459
AJSS DIAGRAM 460
FUNCTION OF AJSS 461
NEUTRALIZER FUNCTION OF AJSS 462
NEUTRAL INTERLOCK FUNCTION OF AJSS 462
SPEED SENSING STEERING FUNCTION OF AJSS 463
TURN SIGNAL PILOT LAMP CONTROL FUNCTION OF AJSS 464
STEERING COLUMN 465
STRUCTURE OF STEERING COLUMN 465
COMPONENT PARTS OF STEERING SYSTEM 466
AJSS EPC VALVE 466
STEERING LOCK VALVE 467
ROTARY VALVE 468
ORBITROL VALVE 471
STOP VALVE 475
STEERING VALVE 476
SECONDARY STEERING PUMP 488
SECONDARY STEERING MOTOR 489
BRAKE SYSTEM 490
LAYOUT DRAWING OF BRAKE SYSTEM 490
LAYOUT DRAWING OF BRAKE COOLING SYSTEM 492
PARKING BRAKE CONTROL SYSTEM 493
PARKING BRAKE CONTROL SYSTEM DIAGRAM 493
OPERATION OF PARKING BRAKE CONTROL SYSTEM 493
BRAKE COOLING CONTROL SYSTEM 495
BRAKE COOLING CONTROL SYSTEM DIAGRAM 495
FUNCTION OF BRAKE COOLING CONTROL SYSTEM 495
COMPONENT PARTS OF BRAKE SYSTEM 496
CHARGE VALVE 496
PARKING BRAKE SOLENOID VALVE 502
PARKING BRAKE EMERGENCY RELEASE VALVE 504
BRAKE CIRCUIT ACCUMULATOR 505
BRAKE VALVE 507
SLACK ADJUSTER 511
BRAKE 513
PARKING BRAKE 516
FLOW PRIORITY VALVE 518
BRAKE COOLING MOTOR 520
BRAKE COOLING PUMP 521
BRAKE COOLING OIL COOLER 522
AUTO-GREASING SYSTEM 523
LAYOUT DRAWING OF AUTO-GREASING SYSTEM 523
SPECIFICATIONS OF AUTO-GREASING SYSTEM 524
FUNCTION OF AUTO-GREASING SYSTEM 526
COMPONENT PARTS OF AUTO-GREASING SYSTEM 527
AUTO-GREASING PUMP 527
UNDERCARRIAGE AND FRAME 528
FRAME, AXLE MOUNT AND CENTER HINGE PIN 528
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 528
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 528
TIRE 530
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE 530
STRUCTURE OF RADIAL TIRE 530
FUNCTION OF RADIAL TIRE 530
STRUCTURE OF BIAS TIRE 531
FUNCTION OF BIAS TIRE 531
WORK EQUIPMENT 532
STRUCTURE OF WORK EQUIPMENT 532
STRUCTURE OF BUCKET 533
CAB AND ITS ATTACHMENTS 534
ROPS CAB 534
STRUCTURE OF ROPS CAB 534
FUNCTION OF ROPS CAB 534
20 STANDARD VALUE TABLE 535
CONTENTS 536
ABBREVIATION LIST 537
STANDARD VALUE TABLE FOR ENGINE 543
STANDARD VALUE TABLE FOR ENGINE: WA480-8 543
STANDARD VALUE TABLE FOR MACHINE 547
STANDARD VALUE TABLE FOR MACHINE: WA480-8 547
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 570
30 TESTING AND ADJUSTING 575
CONTENTS 576
ABBREVIATION LIST 580
RELATED INFORMATION ON TESTING AND ADJUSTING 586
TOOLS FOR TESTING AND ADJUSTING 586
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 595
ENGINE AND COOLING SYSTEM 597
TEST ENGINE SPEED 597
METHOD FOR TESTING ENGINE SPEED 597
TEST BOOST PRESSURE 602
METHOD FOR TESTING BOOST PRESSURE 602
TESTING EXHAUST GAS TEMPERATURE 605
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 605
TEST EXHAUST GAS COLOR 607
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 607
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 608
TEST AND ADJUST VALVE CLEARANCE 609
METHOD FOR TESTING VALVE CLEARANCE 609
METHOD FOR ADJUSTING VALVE CLEARANCE 611
TEST COMPRESSION PRESSURE 612
METHOD FOR TESTING COMPRESSION PRESSURE 612
TEST BLOWBY PRESSURE 616
METHOD FOR TESTING BLOWBY PRESSURE 616
TEST ENGINE OIL PRESSURE 619
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 619
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 619
TEST EGR VALVE AND VGT OIL PRESSURE 621
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 621
TEST FUEL PRESSURE 622
METHOD FOR TESTING FUEL PRESSURE 622
TEST FUEL RETURN RATE AND LEAKAGE 624
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 625
BLEEDING AIR FROM FUEL SYSTEM 628
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 629
TEST FUEL CIRCUIT FOR LEAKAGE 630
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 630
HANDLE CYLINDER CUT-OUT MODE OPERATION 632
HANDLE NO-INJECTION CRANKING OPERATION 633
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 634
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 634
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 635
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 635
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 636
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 636
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 637
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 637
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 637
TEST ALTERNATOR BELT 639
METHOD FOR TESTING ALTERNATOR BELT 639
TEST AUTOMATIC TENSIONER 641
METHOD FOR TESTING AUTOMATIC TENSIONER 641
CLEAN FUEL DOSER 644
METHOD FOR CLEANING FUEL DOSER 644
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 646
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 646
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 653
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 653
TEST SCR RELATED FUNCTIONS 654
TEST AdBlue/DEF PUMP RAISED PRESSURE 658
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 661
TEST AdBlue/DEF LINE HEATER RELAY 1 666
TEST AdBlue/DEF LINE HEATER RELAY 2 670
TEST AdBlue/DEF PUMP HEATER RELAY 674
TEST AdBlue/DEF TANK HEATER VALVE 678
TEST SCR NOx REMOVAL EFFICIENCY 682
CLEAN AdBlue/DEF TANK 686
METHOD FOR CLEANING AdBlue/DEF TANK 686
POWER TRAIN 690
TEST AND ADJUST POWER TRAIN OIL PRESSURE 690
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 692
METHOD FOR ADJUSTING POWER TRAIN OIL PRESSURE 710
ADJUST TRANSMISSION INPUT SPEED SENSOR 712
METHOD FOR ADJUSTING TRANSMISSION INPUT SPEED SENSOR 712
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 714
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR 714
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 715
METHOD FOR FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 715
MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 718
METHOD FOR MOVING DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 719
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 722
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 722
STEERING SYSTEM 723
TEST STEERING WHEEL 723
METHOD FOR TESTING STEERING WHEEL 723
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 725
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE 725
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 729
BLEED AIR FROM STEERING CYLINDER CIRCUIT 731
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT 731
TEST AND ADJUST STEERING STOP VALVE 733
METHOD FOR TESTING STEERING STOP VALVE 733
METHOD FOR ADJUSTING STEERING STOP VALVE 733
BRAKE SYSTEM 734
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 734
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 734
TEST WHEEL BRAKE OIL PRESSURE 735
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE 735
TEST AND ADJUST ACCUMULATOR CHARGE PRESSURE 737
METHOD FOR TESTING ACCUMULATOR CHARGE PRESSURE 737
METHOD FOR ADJUSTING ACCUMULATOR CHARGE PRESSURE 738
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 739
METHOD FOR TESTING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 739
METHOD FOR CHARGING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 741
BLEED AIR FROM BRAKE CIRCUIT 744
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT 744
TEST BRAKING PERFORMANCE 748
METHOD FOR TESTING BRAKING PERFORMANCE 748
TEST BRAKE PEDAL 749
METHOD FOR TESTING BRAKE PEDAL 749
TEST AND ADJUST BRAKE PEDAL AND LINKAGE 750
METHOD FOR TESTING BRAKE PEDAL AND LINKAGE 750
METHOD FOR ADJUSTING BRAKE PEDAL AND LINKAGE 750
TEST LOWERING OF WHEEL BRAKE PRESSURE 751
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE 752
TEST WEAR OF WHEEL BRAKE DISC 754
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC 754
TEST PARKING BRAKE OIL PRESSURE 756
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE 756
TEST PARKING BRAKE PERFORMANCE 758
METHOD FOR TESTING PARKING BRAKE PERFORMANCE 758
RELEASE PARKING BRAKE MANUALLY 759
METHOD FOR RELEASING PARKING BRAKE MANUALLY 759
TEST WEAR AMOUNT OF PARKING BRAKE DISC 762
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC 762
HYDRAULIC SYSTEM 764
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 764
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 764
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE 766
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE 766
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE 770
TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE 772
METHOD FOR TESTING WORK EQUIPMENT EPC OIL PRESSURE 772
METHOD FOR ADJUSTING WORK EQUIPMENT EPC OIL PRESSURE 775
BLEED AIR FROM WORK EQUIPMENT CIRCUIT 777
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 777
TEST COOLING FAN SPEED 778
METHOD FOR TESTING COOLING FAN SPEED 778
TEST COOLING FAN CIRCUIT OIL PRESSURE 779
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 779
BLEED AIR FROM COOLING FAN CIRCUIT 782
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT 782
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS 784
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE 784
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS 786
WORK EQUIPMENT 790
TEST AND ADJUST BUCKET POTENTIOMETER LEVER 790
METHOD FOR TESTING BUCKET POTENTIOMETER LEVER 790
METHOD FOR ADJUSTING BUCKET POTENTIOMETER LEVER 790
TEST AND ADJUST BOOM POTENTIOMETER LEVER 791
METHOD FOR TESTING BOOM POTENTIOMETER LEVER 791
METHOD FOR ADJUSTING BOOM POTENTIOMETER LEVER 791
CAB AND ITS ATTACHMENTS 792
TEST DIRECTIONAL LEVER 792
METHOD FOR TESTING DIRECTIONAL LEVER 792
TEST WORK EQUIPMENT CONTROL LEVER 793
METHOD FOR TESTING WORK EQUIPMENT CONTROL LEVER 793
TEST AJSS LEVER (FOR AJSS SPEC) 796
METHOD FOR TESTING AJSS LEVER 796
TEST STEERING LOCK LEVER(FOR AJSS SPEC) 799
METHOD FOR TESTING OF STEERING LOCK LEVER 799
TEST AND ADJUST AJSS LEVER/FRAME ANGLE SENSOR (FOR AJSS SPEC) 800
METHOD FOR TESTING AJSS LEVER/FRAME ANGLE SENSOR 800
METHOD FOR ADJUSTING AJSS LEVER/FRAME ANGLE SENSOR 800
TEST AND AJUST STEERING STOPPER BOLT (FOR AJSS SPEC) 802
METHOD FOR TESTING STEERING STOPPER VALVE 802
METHOD FOR ADJUSTING STEERING STOPPER VALVE 802
ADJUST RATTLING OPERATOR’S SEAT 804
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 804
ELECTRICAL SYSTEM 805
SET AND ADJUST EACH EQUIPMENT 805
PREPARATION FOR TRANSMISSION ECMV CURRENT ADJUSTMENT 809
METHOD FOR ADJUSTING TRANSMISSION ECMV CURRENT 811
METHOD FOR SETTING AND RESETTING TRANSMISSION INITIAL LEARNING 814
SET AND OPERATE MACHINE MONITOR 819
OPERATOR MODE 823
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 823
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 823
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 824
CHECKING FUNCTION OF SERVICE METER AND ODOMETER 825
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 825
SERVICE MODE 829
METHOD FOR OPERATING SERVICE MODE 829
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 832
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 847
ABNORMALITY RECORD MENU 863
METHOD FOR CONFIRMING MAINTENANCE RECORD 868
METHOD FOR OPERATING MAINTENANCE MODE SETTING 870
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 875
DEFAULT MENU 877
DIAGNOSTIC TESTS MENU 893
ADJUSTMENT MENU 905
METHOD FOR PERFORMING NO-INJECTION CRANKING 943
KOMTRAX SETTINGS MENU 946
METHOD FOR DISPLAYING SERVICE MESSAGE 948
METHOD FOR STARTING UP KOMTRAX TERMINAL 950
ADJUST REARVIEW CAMERA ANGLE 955
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 955
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 957
HANDLE BATTERY DISCONNECT SWITCH 958
TEST DIODES 959
METHOD FOR TESTING DIODE USING DIGITAL TESTER 959
METHOD FOR TESTING DIODE USING ANALOG TESTER 959
AUTO-GREASING DEVICE 960
BLEED THE AIR OF AUTO-GREASING SYSTEM 960
METHOD FOR BLEEDING THE AIR OF AUTO-GREASING SYSTEM 960
CORREPONDENCE IN CASE OF GREASE LEAKAGE FROM OVER PRESSURE PROTECTION VALVE 963
CORREPONDING METHOD FOR GREASE LEAKAGE FROM OVER PRESSURE PROTECTION VALVE 963
CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 964
METHOD FOR CHANGING THE LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 965
Pm CLINIC 967
Pm CLINIC SERVICE 967
Pm CLINIC CHECK SHEET: WA480-8 970
40 TROUBLESHOOTING 981
CONTENTS 982
ABBREVIATION LIST 995
RELATED INFORMATION ON TROUBLESHOOTING 1001
GENERAL TROUBLESHOOTING POINTS 1001
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 1002
SEQUENCE OF EVENTS IN TROUBLESHOOTING 1014
CHECKS BEFORE TROUBLESHOOTING 1016
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 1018
WALK-AROUND CHECK 1018
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 1020
CHECK FUEL LEVEL AND TYPE 1020
CHECK IMPURE INGREDIENT IN FUEL 1020
CHECK AdBule/DEF LEVEL AND TYPE 1021
CHECK FUEL PREFILTER 1021
CHECK MAIN FILTER 1023
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 1024
CHECK COOLANT LEVEL (RESERVOIR TANK) 1024
CHECK CLOGGING OF AIR CLEANER 1025
OUTER ELEMENT – CLEAN 1026
REPLACE ELEMENT 1028
CHECK HYDRAULIC OIL LEVEL 1029
CHECK HYDRAULIC OIL STRAINER 1030
CHECK HYDRAULIC FILTER 1031
CHECK OIL LEVEL IN TRANSMISSION CASE 1032
CHECK OIL LEVEL IN FRONT AXLE CASE 1034
CHECK OIL LEVEL IN REAR AXLE CASE 1035
BLEED AIR FROM FUEL SYSTEM 1035
BLEED AIR FROM HYDRAULIC SYSTEM 1035
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 1035
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 1041
PROCEDURE FOR TESTING AND TROUBLESHOOTING 1053
SYMPTOM AND TROUBLESHOOTING NUMBERS 1055
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1060
CONNECTORS LIST AND LAYOUT 1062
CONNECTOR CONTACT IDENTIFICATION 1089
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1129
FUSE LOCATION TABLE 1135
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1139
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 1143
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 1145
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 1151
FAILURE CODES TABLE 1153
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1177
FAILURE CODE [1500L0] 1177
FAILURE CODE [15SAL1] 1178
FAILURE CODE [15SALH] 1180
FAILURE CODE [15SBL1] 1182
FAILURE CODE [15SBLH] 1184
FAILURE CODE [15SEL1] 1186
FAILURE CODE [15SELH] 1188
FAILURE CODE [15SFL1] 1190
FAILURE CODE [15SFLH] 1192
FAILURE CODE [15SGL1] 1194
FAILURE CODE [15SGLH] 1196
FAILURE CODE [15SHL1] 1198
FAILURE CODE [15SHLH] 1200
FAILURE CODE [2F00MA] 1203
FAILURE CODE [2F00MB] 1207
FAILURE CODE [2G42ZG] 1210
FAILURE CODE [2G43ZG] 1212
FAILURE CODE [879AKA] 1214
FAILURE CODE [879AKB] 1216
FAILURE CODE [879BKA] 1218
FAILURE CODE [879BKB] 1220
FAILURE CODE [879CKA] 1222
FAILURE CODE [879CKB] 1224
FAILURE CODE [879DKZ] 1226
FAILURE CODE [879EMC] 1228
FAILURE CODE [879FMC] 1231
FAILURE CODE [989A00] 1234
FAILURE CODE [989L00] 1235
FAILURE CODE [989M00] 1236
FAILURE CODE [989N00] 1237
FAILURE CODE [A1U0N3] 1238
FAILURE CODE [A1U0N4] 1240
FAILURE CODE [AA10NX] 1242
FAILURE CODE [AB00KE] 1244
FAILURE CODE [AB00KY] 1246
FAILURE CODE [AQ10N3] 1248
FAILURE CODE [AS00N3] 1250
FAILURE CODE [AS00R2] 1252
FAILURE CODE [AS00R3] 1253
FAILURE CODE [AS00R4] 1254
FAILURE CODE [AS00R5] 1255
FAILURE CODE [AS00R6] 1256
FAILURE CODE [AS00ZK] 1257
FAILURE CODE [AS10KM] 1258
FAILURE CODE [AS10NR] 1259
FAILURE CODE [AS10NT] 1260
FAILURE CODE [B@BAZG] 1261
FAILURE CODE [B@BAZK] 1262
FAILURE CODE [B@BCNS] 1264
FAILURE CODE [B@BCZK] 1265
FAILURE CODE [B@C7NS] 1267
FAILURE CODE [B@CENS] 1269
FAILURE CODE [B@HANS] 1270
FAILURE CODE [CA115] 1271
FAILURE CODE [CA122] 1272
FAILURE CODE [CA123] 1274
FAILURE CODE [CA131] 1276
FAILURE CODE [CA132] 1278
FAILURE CODE [CA135] 1281
FAILURE CODE [CA141] 1283
FAILURE CODE [CA144] 1285
FAILURE CODE [CA145] 1287
FAILURE CODE [CA153] 1289
FAILURE CODE [CA154] 1292
FAILURE CODE [CA187] 1295
FAILURE CODE [CA221] 1297
FAILURE CODE [CA222] 1299
FAILURE CODE [CA227] 1301
FAILURE CODE [CA234] 1302
FAILURE CODE [CA238] 1303
FAILURE CODE [CA239] 1305
FAILURE CODE [CA249] 1307
FAILURE CODE [CA256] 1309
FAILURE CODE [CA271] 1311
FAILURE CODE [CA272] 1313
FAILURE CODE [CA273] 1314
FAILURE CODE [CA274] 1316
FAILURE CODE [CA322] 1317
FAILURE CODE [CA323] 1319
FAILURE CODE [CA324] 1321
FAILURE CODE [CA325] 1323
FAILURE CODE [CA331] 1325
FAILURE CODE [CA332] 1327
FAILURE CODE [CA343] 1329
FAILURE CODE [CA351] 1330
FAILURE CODE [CA352] 1331
FAILURE CODE [CA356] 1334
FAILURE CODE [CA357] 1336
FAILURE CODE [CA386] 1338
FAILURE CODE [CA431] 1339
FAILURE CODE [CA432] 1342
FAILURE CODE [CA441] 1346
FAILURE CODE [CA442] 1348
FAILURE CODE [CA449] 1349
FAILURE CODE [CA451] 1350
FAILURE CODE [CA452] 1352
FAILURE CODE [CA515] 1354
FAILURE CODE [CA516] 1356
FAILURE CODE [CA553] 1358
FAILURE CODE [CA555] 1359
FAILURE CODE [CA556] 1360
FAILURE CODE [CA559] 1361
FAILURE CODE [CA595] 1366
FAILURE CODE [CA687] 1367
FAILURE CODE [CA689] 1369
FAILURE CODE [CA691] 1371
FAILURE CODE [CA692] 1373
FAILURE CODE [CA697] 1375
FAILURE CODE [CA698] 1376
FAILURE CODE [CA731] 1377
FAILURE CODE [CA778] 1378
FAILURE CODE [CA1117] 1381
FAILURE CODE [CA1664] 1382
FAILURE CODE [CA1669] 1385
FAILURE CODE [CA1673] 1386
FAILURE CODE [CA1677] 1387
FAILURE CODE [CA1678] 1388
FAILURE CODE [CA1682] 1389
FAILURE CODE [CA1683] 1393
FAILURE CODE [CA1684] 1395
FAILURE CODE [CA1686] 1397
FAILURE CODE [CA1691] 1398
FAILURE CODE [CA1694] 1401
FAILURE CODE [CA1695] 1403
FAILURE CODE [CA1696] 1404
FAILURE CODE [CA1712] 1406
FAILURE CODE [CA1713] 1409
FAILURE CODE [CA1714] 1411
FAILURE CODE [CA1715] 1412
FAILURE CODE [CA1776] 1413
FAILURE CODE [CA1777] 1416
FAILURE CODE [CA1843] 1419
FAILURE CODE [CA1844] 1421
FAILURE CODE [CA1879] 1424
FAILURE CODE [CA1881] 1427
FAILURE CODE [CA1883] 1429
FAILURE CODE [CA1885] 1433
FAILURE CODE [CA1887] 1435
FAILURE CODE [CA1921] 1437
FAILURE CODE [CA1922] 1440
FAILURE CODE [CA1923] 1445
FAILURE CODE [CA1924] 1447
FAILURE CODE [CA1925] 1449
FAILURE CODE [CA1927] 1451
FAILURE CODE [CA1928] 1453
FAILURE CODE [CA1942] 1455
FAILURE CODE [CA1963] 1456
FAILURE CODE [CA1977] 1460
FAILURE CODE [CA1993] 1463
FAILURE CODE [CA2185] 1466
FAILURE CODE [CA2186] 1468
FAILURE CODE [CA2249] 1470
FAILURE CODE [CA2265] 1471
FAILURE CODE [CA2266] 1473
FAILURE CODE [CA2271] 1476
FAILURE CODE [CA2272] 1478
FAILURE CODE [CA2349] 1480
FAILURE CODE [CA2353] 1482
FAILURE CODE [CA2357] 1484
FAILURE CODE [CA2381] 1485
FAILURE CODE [CA2382] 1487
FAILURE CODE [CA2383] 1489
FAILURE CODE [CA2386] 1491
FAILURE CODE [CA2387] 1493
FAILURE CODE [CA2555] 1494
FAILURE CODE [CA2556] 1496
FAILURE CODE [CA2637] 1498
FAILURE CODE [CA2639] 1500
FAILURE CODE [CA2732] 1503
FAILURE CODE [CA2733] 1505
FAILURE CODE [CA2741] 1507
FAILURE CODE [CA2765] 1508
FAILURE CODE [CA2771] 1509
FAILURE CODE [CA2777] 1515
FAILURE CODE [CA2878] 1518
FAILURE CODE [CA2881] 1521
FAILURE CODE [CA2976] 1524
FAILURE CODE [CA3133] 1526
FAILURE CODE [CA3134] 1528
FAILURE CODE [CA3135] 1530
FAILURE CODE [CA3142] 1534
FAILURE CODE [CA3143] 1535
FAILURE CODE [CA3144] 1536
FAILURE CODE [CA3146] 1539
FAILURE CODE [CA3147] 1540
FAILURE CODE [CA3148] 1541
FAILURE CODE [CA3151] 1543
FAILURE CODE [CA3165] 1549
FAILURE CODE [CA3167] 1551
FAILURE CODE [CA3229] 1554
FAILURE CODE [CA3231] 1556
FAILURE CODE [CA3232] 1558
FAILURE CODE [CA3235] 1562
FAILURE CODE [CA3239] 1564
FAILURE CODE [CA3241] 1567
FAILURE CODE [CA3242] 1570
FAILURE CODE [CA3251] 1573
FAILURE CODE [CA3253] 1575
FAILURE CODE [CA3254] 1578
FAILURE CODE [CA3255] 1581
FAILURE CODE [CA3256] 1585
FAILURE CODE [CA3311] 1587
FAILURE CODE [CA3312] 1589
FAILURE CODE [CA3313] 1592
FAILURE CODE [CA3314] 1593
FAILURE CODE [CA3315] 1594
FAILURE CODE [CA3316] 1597
FAILURE CODE [CA3317] 1598
FAILURE CODE [CA3318] 1599
FAILURE CODE [CA3319] 1602
FAILURE CODE [CA3321] 1603
FAILURE CODE [CA3322] 1605
FAILURE CODE [CA3419] 1608
FAILURE CODE [CA3421] 1610
FAILURE CODE [CA3497] 1612
FAILURE CODE [CA3498] 1613
FAILURE CODE [CA3543] 1614
FAILURE CODE [CA3545] 1621
FAILURE CODE [CA3547] 1623
FAILURE CODE [CA3558] 1624
FAILURE CODE [CA3559] 1626
FAILURE CODE [CA3562] 1628
FAILURE CODE [CA3563] 1630
FAILURE CODE [CA3567] 1633
FAILURE CODE [CA3568] 1636
FAILURE CODE [CA3571] 1642
FAILURE CODE [CA3572] 1644
FAILURE CODE [CA3574] 1646
FAILURE CODE [CA3575] 1648
FAILURE CODE [CA3577] 1650
FAILURE CODE [CA3578] 1652
FAILURE CODE [CA3582] 1654
FAILURE CODE [CA3583] 1662
FAILURE CODE [CA3596] 1664
FAILURE CODE [CA3649] 1667
FAILURE CODE [CA3681] 1669
FAILURE CODE [CA3682] 1674
FAILURE CODE [CA3713] 1680
FAILURE CODE [CA3717] 1683
FAILURE CODE [CA3718] 1684
FAILURE CODE [CA3725] 1685
FAILURE CODE [CA3748] 1688
FAILURE CODE [CA3751] 1691
FAILURE CODE [CA3755] 1693
FAILURE CODE [CA3866] 1695
FAILURE CODE [CA3867] 1698
FAILURE CODE [CA3868] 1701
FAILURE CODE [CA3899] 1705
FAILURE CODE [CA3911] 1707
FAILURE CODE [CA3912] 1711
FAILURE CODE [CA3932] 1713
FAILURE CODE [CA3933] 1715
FAILURE CODE [CA3934] 1717
FAILURE CODE [CA3935] 1720
FAILURE CODE [CA3936] 1722
FAILURE CODE [CA4151] 1724
FAILURE CODE [CA4152] 1728
FAILURE CODE [CA4155] 1732
FAILURE CODE [CA4156] 1734
FAILURE CODE [CA4157] 1737
FAILURE CODE [CA4158] 1739
FAILURE CODE [CA4159] 1740
FAILURE CODE [CA4161] 1741
FAILURE CODE [CA4162] 1744
FAILURE CODE [CA4163] 1747
FAILURE CODE [CA4164] 1749
FAILURE CODE [CA4165] 1751
FAILURE CODE [CA4166] 1753
FAILURE CODE [CA4168] 1755
FAILURE CODE [CA4169] 1758
FAILURE CODE [CA4171] 1760
FAILURE CODE [CA4249] 1763
FAILURE CODE [CA4251] 1765
FAILURE CODE [CA4259] 1767
FAILURE CODE [CA4261] 1770
FAILURE CODE [CA4277] 1773
FAILURE CODE [CA4281] 1776
FAILURE CODE [CA4459] 1779
FAILURE CODE [CA4461] 1782
FAILURE CODE [CA4658] 1785
FAILURE CODE [CA4731] 1789
FAILURE CODE [CA4732] 1790
FAILURE CODE [CA4739] 1791
FAILURE CODE [CA4768] 1792
FAILURE CODE [CA4769] 1794
FAILURE CODE [CA4842] 1797
FAILURE CODE [CA4952] 1800
FAILURE CODE [CA5115] 1802
FAILURE CODE [CA5179] 1805
FAILURE CODE [CA5181] 1807
FAILURE CODE [CA5383] 1809
FAILURE CODE [D150KA] 1811
FAILURE CODE [D150KB] 1813
FAILURE CODE [D150KY] 1815
FAILURE CODE [D160KA] 1817
FAILURE CODE [D160KB] 1819
FAILURE CODE [D160KY] 1821
FAILURE CODE [D191KA] 1823
FAILURE CODE [D191KB] 1826
FAILURE CODE [D191KY] 1829
FAILURE CODE [D192KA] 1831
FAILURE CODE [D192KB] 1833
FAILURE CODE [D192KY] 1835
FAILURE CODE [D19JKZ] 1836
FAILURE CODE [D1E6KA] 1838
FAILURE CODE [D1E6KB] 1840
FAILURE CODE [D1E6KY] 1842
FAILURE CODE [D5ZHKA] 1844
FAILURE CODE [D5ZHKB] 1846
FAILURE CODE [D5ZHKZ] 1848
FAILURE CODE [D5ZHL6] 1851
FAILURE CODE [D811MC] 1853
FAILURE CODE [D862KA] 1854
FAILURE CODE [D8ALKA] 1855
FAILURE CODE [D8ALKB] 1857
FAILURE CODE [D8AQK4] 1859
FAILURE CODE [D8AQKR] 1860
FAILURE CODE [DAF0KT] 1862
FAILURE CODE [DAF0MB] 1863
FAILURE CODE [DAF0MC] 1864
FAILURE CODE [DAF3KK] 1865
FAILURE CODE [DAF8KB] 1867
FAILURE CODE [DAFDKB] 1869
FAILURE CODE [DAFGMC] 1871
FAILURE CODE [DAFLKA] 1872
FAILURE CODE [DAFLKB] 1874
FAILURE CODE [DAFQKR] 1876
FAILURE CODE [DAQ0KK] 1877
FAILURE CODE [DAQ0KT] 1880
FAILURE CODE [DAQ0MC] 1881
FAILURE CODE [DAQ1KA] 1882
FAILURE CODE [DAQ2KK] 1884
FAILURE CODE [DAQ4KB] 1887
FAILURE CODE [DAQ9KQ] 1889
FAILURE CODE [DAQLKA] 1890
FAILURE CODE [DAQLKB] 1892
FAILURE CODE [DAQQKR] 1894
FAILURE CODE [DAQRKR] 1895
FAILURE CODE [DAQRMA] 1896
FAILURE CODE [DAZ9KQ] 1897
FAILURE CODE [DAZQKR] 1898
FAILURE CODE [DB2QKR] 1899
FAILURE CODE [DB2RKR] 1904
FAILURE CODE [DB90KK] 1910
FAILURE CODE [DB90KT] 1913
FAILURE CODE [DB90MC] 1914
FAILURE CODE [DB91KA] 1915
FAILURE CODE [DB92KK] 1917
FAILURE CODE [DB95KX] 1920
FAILURE CODE [DB96KX] 1923
FAILURE CODE [DB99KQ] 1925
FAILURE CODE [DB9LKA] 1926
FAILURE CODE [DB9LKB] 1928
FAILURE CODE [DB9QKR] 1930
FAILURE CODE [DB9RKR] 1931
FAILURE CODE [DB9RMA] 1932
FAILURE CODE [DBE5KX] 1933
FAILURE CODE [DBE6KX] 1935
FAILURE CODE [DD1ALD] 1937
FAILURE CODE [DDAAL6] 1939
FAILURE CODE [DDB6L4] 1941
FAILURE CODE [DDD1LD] 1944
FAILURE CODE [DDK3KA] 1946
FAILURE CODE [DDK3KB] 1949
FAILURE CODE [DDK4KA] 1952
FAILURE CODE [DDK4KB] 1955
FAILURE CODE [DDK5L4] 1957
FAILURE CODE [DDK6KA] 1959
FAILURE CODE [DDK6KB] 1962
FAILURE CODE [DDKLKA] 1965
FAILURE CODE [DDKLKB] 1968
FAILURE CODE [DDNRKY] 1970
FAILURE CODE [DDP5KA] 1972
FAILURE CODE [DDT0L4] 1974
FAILURE CODE [DDT4LD] 1976
FAILURE CODE [DDT9LD] 1978
FAILURE CODE [DDTALD] 1980
FAILURE CODE [DDW9LD] 1982
FAILURE CODE [DDWLLD] 1984
FAILURE CODE [DF10KA] 1986
FAILURE CODE [DF10KB] 1989
FAILURE CODE [DGF1KA] 1992
FAILURE CODE [DGF1KB] 1994
FAILURE CODE [DGH2KX] 1996
FAILURE CODE [DGR2KB] 1998
FAILURE CODE [DGR2KZ] 2000
FAILURE CODE [DGT1KA] 2002
FAILURE CODE [DGT1KB] 2004
FAILURE CODE [DH21KA] 2006
FAILURE CODE [DH21KB] 2009
FAILURE CODE [DHA4KA] 2011
FAILURE CODE [DHAAMA] 2013
FAILURE CODE [DHACMA] 2015
FAILURE CODE [DHPCKX] 2017
FAILURE CODE [DHPDKX] 2020
FAILURE CODE [DHT1KX] 2023
FAILURE CODE [DHT5KX] 2026
FAILURE CODE [DHT7KX] 2029
FAILURE CODE [DHT8KA] 2032
FAILURE CODE [DHT8KB] 2035
FAILURE CODE [DHT8ZG] 2037
FAILURE CODE [DHUDKA] 2038
FAILURE CODE [DHUDKB] 2041
FAILURE CODE [DJF1KA] 2043
FAILURE CODE [DK30KA] 2045
FAILURE CODE [DK30KY] 2047
FAILURE CODE [DK55KA] 2049
FAILURE CODE [DK55KY] 2052
FAILURE CODE [DK55L5] 2054
FAILURE CODE [DK59KA] 2055
FAILURE CODE [DK59KY] 2059
FAILURE CODE [DK59L8] 2063
FAILURE CODE [DK5AKA] 2068
FAILURE CODE [DK5AKY] 2072
FAILURE CODE [DK5BKA] 2076
FAILURE CODE [DK5BKY] 2080
FAILURE CODE [DK5BL8] 2084
FAILURE CODE [DK5CKA] 2089
FAILURE CODE [DK5CKY] 2093
FAILURE CODE [DK5DKA] 2097
FAILURE CODE [DK5DKY] 2100
FAILURE CODE [DK5DL8] 2103
FAILURE CODE [DK5EKA] 2107
FAILURE CODE [DK5EKY] 2110
FAILURE CODE [DKA0KA] 2113
FAILURE CODE [DKA0KY] 2116
FAILURE CODE [DKA0L0] 2119
FAILURE CODE [DKA1KA] 2122
FAILURE CODE [DKA1KY] 2125
FAILURE CODE [DKD0KA] 2128
FAILURE CODE [DKD0KY] 2130
FAILURE CODE [DKD0L8] 2132
FAILURE CODE [DLF1KA] 2133
FAILURE CODE [DLF1LC] 2135
FAILURE CODE [DLM3KA] 2137
FAILURE CODE [DLM3LC] 2139
FAILURE CODE [DLT3KA] 2141
FAILURE CODE [DLT3LC] 2143
FAILURE CODE [DPQ1KR] 2145
FAILURE CODE [DPQ2KR] 2148
FAILURE CODE [DPQ3KR] 2151
FAILURE CODE [DSJ0KR] 2154
FAILURE CODE [DT20KB] 2157
FAILURE CODE [DT22KB] 2159
FAILURE CODE [DT23KB] 2161
FAILURE CODE [DV00KB] 2163
FAILURE CODE [DW4PKA] 2165
FAILURE CODE [DW4PKB] 2167
FAILURE CODE [DW4PKY] 2169
FAILURE CODE [DW4QKA] 2171
FAILURE CODE [DW4QKB] 2173
FAILURE CODE [DW4QKY] 2175
FAILURE CODE [DW4RKA] 2177
FAILURE CODE [DW4RKB] 2179
FAILURE CODE [DW4RKY] 2181
FAILURE CODE [DW4SKA] 2183
FAILURE CODE [DW4SKB] 2185
FAILURE CODE [DW4SKY] 2187
FAILURE CODE [DW7BKA] 2189
FAILURE CODE [DW7BKB] 2191
FAILURE CODE [DW7BKY] 2193
FAILURE CODE [DWM1KA] 2195
FAILURE CODE [DWM1KB] 2197
FAILURE CODE [DWM1KY] 2199
FAILURE CODE [DWN6KA] 2201
FAILURE CODE [DWN6KB] 2203
FAILURE CODE [DWN6KY] 2205
FAILURE CODE [DWN8KA] 2207
FAILURE CODE [DWN8KB] 2209
FAILURE CODE [DWN8KY] 2211
FAILURE CODE [DX16KA] 2213
FAILURE CODE [DX16KB] 2215
FAILURE CODE [DX16KY] 2217
FAILURE CODE [DXA1KA] 2219
FAILURE CODE [DXA1KB] 2221
FAILURE CODE [DXA1KY] 2223
FAILURE CODE [DXANKA] 2225
FAILURE CODE [DXANKB] 2227
FAILURE CODE [DXANKY] 2229
FAILURE CODE [DXF0KA] 2231
FAILURE CODE [DXF0KB] 2233
FAILURE CODE [DXF0KY] 2235
FAILURE CODE [DXH1KA] 2237
FAILURE CODE [DXH1KB] 2239
FAILURE CODE [DXH1KY] 2241
FAILURE CODE [DXH4KA] 2243
FAILURE CODE [DXH4KB] 2245
FAILURE CODE [DXH4KY] 2247
FAILURE CODE [DXH5KA] 2249
FAILURE CODE [DXH5KB] 2251
FAILURE CODE [DXH5KY] 2253
FAILURE CODE [DXH6KA] 2255
FAILURE CODE [DXH6KB] 2257
FAILURE CODE [DXH6KY] 2259
FAILURE CODE [DXH7KA] 2261
FAILURE CODE [DXH7KB] 2263
FAILURE CODE [DXH7KY] 2265
FAILURE CODE [DXH8KA] 2267
FAILURE CODE [DXH8KB] 2269
FAILURE CODE [DXH8KY] 2271
FAILURE CODE [DXHHKA] 2273
FAILURE CODE [DXHHKB] 2275
FAILURE CODE [DXHHKY] 2277
FAILURE CODE [DXHJKA] 2279
FAILURE CODE [DXHJKB] 2281
FAILURE CODE [DXHJKY] 2283
FAILURE CODE [DXHKKA] 2285
FAILURE CODE [DXHKKB] 2287
FAILURE CODE [DXHKKY] 2289
FAILURE CODE [DY30MA] 2291
FAILURE CODE [DY30MC] 2295
FAILURE CODE [DY30ME] 2300
FAILURE CODE [LA00L3] 2302
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2303
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2303
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 2312
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2315
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2318
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING 2320
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING 2323
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS) 2326
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY 2329
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 2332
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 2335
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 2339
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY 2341
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION 2344
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 2347
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY 2350
E-16 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 2351
E-17 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 2354
E-18 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 2357
E-19 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 2360
E-20 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL 2364
E-21 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP 2366
E-22 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP 2368
E-23 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION 2370
E-24 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 2374
E-25 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 2375
E-26 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2376
E-27 TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP 2378
E-28 INDICATION OF HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT 2379
E-29 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL 2381
E-30 ALARM BUZZER DOES NOT SOUND 2382
E-31 ALARM BUZZER DOES NOT STOP SOUNDING 2384
E-32 KICKDOWN DOES NOT WORK WHEN KICKDOWN SWITCH IS TURNED ON 2385
E-33 HOLD SWITCH DOES NOT WORK WHEN IT IS PRESSED 2387
E-34 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED 2389
E-35 TRANSMISSION CUT-OFF MODE IS NOT SELECTED OR NOT RELEASED 2393
E-36 TRANSMISSION CUT-OFF SETTING CANNOT BE RELEASED 2395
E-37 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED 2397
E-38 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE NORMALLY WHEN ENGINE POWER MODE SELECTOR SWITCH IS OPERATED 2399
E-39 FLOW OF LOADER PUMP DOES NOT INCREASE FROM THE MINIMUM RATE 2401
E-40 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED 2402
E-41 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED (FOR AJSS SPEC) 2404
E-42 HORN DOES NOT SOUND 2406
E-43 HORN DOES NOT SOUND (FOR AJSS SPEC) 2409
E-44 HORN DOES NOT STOP SOUNDING 2412
E-45 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 2415
E-46 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS (FOR AJSS SPEC) 2417
E-47 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT 2419
E-48 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2423
E-49 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2427
E-50 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT 2431
E-51 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2435
E-52 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2439
E-53 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 2443
E-54 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2445
E-55 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2447
E-56 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 2449
E-57 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2451
E-58 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2453
E-59 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT 2455
E-60 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2460
E-61 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT 2465
E-62 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2469
E-63 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT 2474
E-64 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2477
E-65 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT 2480
E-66 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2483
E-67 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2487
E-68 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT 2490
E-69 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2495
E-70 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED 2499
E-71 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT 2503
E-72 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND 2506
E-73 FRONT WIPER DOES NOT OPERATE 2508
E-74 FRONT WIPER DOES NOT OPERATE (FOR AJSS SPEC) 2512
E-75 REAR WIPER DOES NOT OPERATE 2516
E-76 REAR WIPER DOES NOT OPERATE (FOR AJSS SPEC) 2519
E-77 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY 2522
E-78 FAN DOES NOT ROTATE IN REVERSE 2525
E-79 FAN REMAINS ROTATED IN REVERSE 2526
E-80 WINDOW WASHER DOES NOT OPERATE 2527
E-81 WINDOW WASHER DOES NOT OPERATE (FOR AJSS SPEC) 2530
E-82 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2533
E-83 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2534
E-84 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2536
E-85 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP 2537
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2539
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2539
FAILURE MODE AND CAUSE TABLE 2540
H-1 MACHINE DOES NOT START 2560
H-2 LOCKUP IS NOT RELEASED 2564
H-3 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE 2565
H-4 TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADABILITY IS LOW, OR GEAR SPEED DOES NOT SHIFT 2566
H-5 LARGE SHOCK IS MADE WHEN MACHINE MOVES OFF OR GEAR IS SHIFTED 2570
H-6 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED 2573
H-7 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 2576
H-8 MACHINE DOES NOT TURN (FOR STEERING WHEEL SPEC) 2579
H-9 MACHINE DOES NOT TURN (AJSS SPECIFICATION) 2581
H-10 TURNING RESPONSE IS POOR (FOR STEERING WHEEL SPEC) 2583
H-11 TURNING RESPONSE IS POOR (AJSS SPECIFICATION) 2585
H-12 STEERING WHEEL IS HEAVY TO OPERATE 2587
H-13 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (FOR STEERING WHEEL SPEC) 2588
H-14 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (AJSS SPECIFICATION) 2590
H-15 TURNING RADIUS DIFFERS BETWEEN RIGHT AND LEFT TURNS 2592
H-16 WHEEL BRAKES DO NOT WORK OR ARE WEAK 2593
H-17 WHEEL BRAKES ARE NOT RELEASED OR DRAG 2595
H-18 PARKING BRAKE DOES NOT WORK OR IT IS WEAK 2596
H-19 PARKING BRAKE IS NOT RELEASED OR DRAGS 2597
H-20 BOOM DOES NOT RISE 2599
H-21 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE 2601
H-22 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT 2603
H-23 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND 2604
H-24 HYDRAULIC DRIFT OF BOOM IS LARGE 2606
H-25 BOOM MOVES UP AND DOWN DURING OPERATION 2607
H-26 BUCKET DOES NOT TILT BACK 2608
H-27 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE 2610
H-28 BUCKET DECELERATES DURING TILT-BACK OPERATION 2612
H-29 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND 2613
H-30 HYDRAULIC DRIFT OF BUCKET IS LARGE 2615
H-31 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD) 2616
H-32 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE 2617
H-33 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2618
H-34 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS 2619
H-35 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 2622
H-36 E C S S (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES 2623
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2624
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN 2626
TROUBLESHOOTING OF ENGINE (S-MODE) 2627
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2627
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2628
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2629
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2630
S-4 ENGINE STARTABILITY IS POOR 2631
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2633
S-6 ENGINE STOPS DURING OPERATION 2635
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2637
S-8 ENGINE LACKS POWER 2638
S-9 KDPF GETS CLOGGED IN A SHORT TIME 2640
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2642
S-11 OIL BECOMES CONTAMINATED QUICKLY 2643
S-12 FUEL CONSUMPTION IS EXCESSIVE 2644
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2645
S-14 OIL PRESSURE DROPS 2646
S-15 FUEL MIXES INTO ENGINE OIL 2648
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2649
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2650
S-18 UNUSUAL NOISE IS HEARD 2651
S-19 VIBRATION IS EXCESSIVE 2652
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2653
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2654
S-22 ACTIVE REGENERATION TAKES TIME 2656
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2658
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2659
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2661
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2662
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM 2663
OUTLINE OF FAILURE DISPLAY 2663
TROUBLESHOOTING FOR FCS 2664
TROUBLESHOOTING FOR AUTO-GREASING PUMP 2665
REPLACEMENT OF PUMP ELEMENT 2668
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM 2669
REPLACEMENT OF AUTO-GREASING CONTROLLER 2671
PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING 2672
50 DISASSEMBLY AND ASSEMBLY 2673
CONTENTS 2674
ABBREVIATION LIST 2679
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2685
HOW TO READ THIS MANUAL 2685
COATING MATERIALS LIST 2687
SPECIAL TOOLS LIST 2691
SKETCHES OF SPECIAL TOOLS 2712
ENGINE AND COOLING SYSTEM 2718
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2718
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2718
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2722
REMOVE AND INSTALL INJECTOR ASSEMBLY 2728
METHOD FOR REMOVING INJECTOR ASSEMBLY 2728
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2732
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 2740
METHOD FOR REMOVING FUEL DOSER ASSEMBLY 2740
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY 2741
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2744
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2744
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2755
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2772
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2772
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2772
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2774
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2774
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2776
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2779
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2779
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2780
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT 2782
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT 2782
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT 2784
REMOVE AND INSTALL ALTERNATOR BELT 2787
METHOD FOR REMOVING ALTERNATOR BELT 2787
METHOD FOR INSTALLING ALTERNATOR BELT 2788
REMOVE AND INSTALL AUTOMATIC TENSIONER 2790
METHOD FOR REMOVING AUTOMATIC TENSIONER 2790
METHOD FOR INSTALLING AUTOMATIC TENSIONER 2790
REMOVE AND INSTALL RADIATOR ASSEMBLY 2791
METHOD FOR REMOVING RADIATOR ASSEMBLY 2791
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2796
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2801
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2801
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2804
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2806
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2806
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2808
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2810
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2810
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2814
REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY 2818
METHOD FOR REMOVING POWER TRAIN OIL COOLER ASSEMBLY 2818
METHOD FOR INSTALLING POWER TRAIN OIL COOLER ASSEMBLY 2823
REMOVE AND INSTALL ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2829
METHOD FOR REMOVING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2830
METHOD FOR INSTALLING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2847
DISCONNECT AND CONNECT ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2864
METHOD FOR DISCONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2864
METHOD FOR CONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2865
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2867
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2867
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2868
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2871
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2871
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2872
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2879
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2879
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2885
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2892
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2892
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2895
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2900
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2900
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2904
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2908
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2908
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2913
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2917
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2917
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2917
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2919
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2919
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2919
REMOVE AND INSTALL KDPF ASSEMBLY 2920
METHOD FOR REMOVING KDPF ASSEMBLY 2921
METHOD FOR INSTALLING KDPF ASSEMBLY 2934
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2949
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2949
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2953
REMOVE AND INSTALL SCR ASSEMBLY 2959
METHOD FOR REMOVING SCR ASSEMBLY 2960
METHOD FOR INSTALLING SCR ASSEMBLY 2970
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2984
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2985
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2996
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 3007
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY 3007
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY 3012
REMOVE AND INSTALL KCCV ASSEMBLY 3020
METHOD FOR REMOVING KCCV ASSEMBLY 3020
METHOD FOR INSTALLING KCCV ASSEMBLY 3020
REMOVE AND INSTALL VGT ASSEMBLY 3022
METHOD FOR REMOVING VGT ASSEMBLY 3022
METHOD FOR INSTALLING VGT ASSEMBLY 3028
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 3034
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 3035
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 3041
REMOVE AND INSTALL AdBlue/DEF INJECTOR 3051
METHOD FOR REMOVING AdBlue/DEF INJECTOR 3051
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 3055
REMOVE AND INSTALL AdBlue/DEF PUMP 3059
METHOD FOR REMOVING AdBlue/DEF PUMP 3059
METHOD FOR INSTALLING AdBlue/DEF PUMP 3062
REMOVE AND INSTALL AdBlue/DEF HOSE 3065
METHOD FOR REMOVING AdBlue/DEF HOSE 3066
METHOD FOR INSTALLING AdBlue/DEF HOSE 3075
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 3086
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 3086
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 3087
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 3089
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 3089
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 3090
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 3092
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 3092
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 3093
POWER TRAIN 3095
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY 3095
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY 3095
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY 3099
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY 3107
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 3109
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 3127
DISASSEMBLE AND ASSEMBLE TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 3154
METHOD FOR DISASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 3155
METHOD FOR ASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 3171
REMOVE AND INSTALL FRONT AXLE ASSEMBLY 3191
METHOD FOR REMOVING FRONT AXLE ASSEMBLY 3191
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY 3193
REMOVE AND INSTALL REAR AXLE ASSEMBLY 3195
METHOD FOR REMOVING REAR AXLE ASSEMBLY 3195
METHOD FOR INSTALLING REAR AXLE ASSEMBLY 3202
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY 3210
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY 3211
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY 3216
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY 3224
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY 3225
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY 3234
STEERING SYSTEM 3253
REMOVE AND INSTALL STEERING VALVE ASSEMBLY 3253
METHOD FOR REMOVING STEERING VALVE ASSEMBLY 3253
METHOD FOR INSTALLING STEERING VALVE ASSEMBLY 3255
REMOVE AND INSTALL ROTARY VALVE ASSEMBLY (FOR AJSS SPEC) 3258
METHOD FOR REMOVING ROTARY VALVE ASSEMBLY 3258
METHOD FOR INSTALLING ROTARY VALVE ASSEMBLY 3263
BRAKE SYSTEM 3272
REMOVE AND INSTALL PARKING BRAKE DISC AND PLATE 3272
METHOD FOR REMOVING PARKING BRAKE DISC AND PLATE 3272
METHOD FOR INSTALLING PARKING BRAKE DISC AND PLATE 3275
UNDERCARRIAGE AND FRAME 3278
REMOVE AND INSTALL CENTER HINGE PIN 3278
METHOD FOR REMOVING CENTER HINGE PIN 3278
METHOD FOR INSTALLING CENTER HINGE PIN 3284
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 3291
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 3291
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 3293
REMOVE AND INSTALL FULL-LENGTH FENDER ASSEMBLY 3297
METHOD FOR REMOVING FULL-LENGTH FENDER ASSEMBLY 3297
METHOD FOR INSTALLING FULL-LENGTH FENDER ASSEMBLY 3298
HYDRAULIC SYSTEM 3299
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 3299
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 3299
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 3303
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY 3307
METHOD FOR REMOVING WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY 3307
METHOD FOR INSTALLING WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY 3308
REMOVE AND INSTALL STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY 3310
METHOD FOR REMOVING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY 3310
METHOD FOR INSTALLING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY 3311
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 3314
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 3314
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 3317
WORK EQUIPMENT 3321
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 3321
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 3321
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 3325
DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLY 3330
METHOD FOR DISASSEMBLING HYDRAULIC CYLINDER ASSEMBLY 3331
METHOD FOR ASSEMBLING HYDRAULIC CYLINDER ASSEMBLY 3334
CAB AND ITS ATTACHMENTS 3340
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 3340
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 3340
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 3346
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 3353
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) 3353
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) 3354
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 3363
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 3363
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 3369
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 3374
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY 3374
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY 3376
REMOVE AND INSTALL SEAT BELT 3378
METHOD FOR REMOVING SEAT BELT 3378
METHOD FOR INSTALLING SEAT BELT 3378
ELECTRICAL SYSTEM 3380
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 3380
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 3380
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 3382
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY 3385
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY 3385
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY 3386
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 3389
METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY 3389
METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY 3389
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY 3391
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY 3391
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY 3393
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 3395
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 3395
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 3396
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3398
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 3398
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 3399
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 3400
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 3400
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 3401
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR 3402
METHOD FOR REMOVING KDPF TEMPERATURE SENSOR 3402
METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR 3406
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR 3411
METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR 3411
METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR 3415
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 3419
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 3419
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 3423
REMOVE AND INSTALL AMMONIA SENSOR 3427
METHOD FOR REMOVING AMMONIA SENSOR 3427
METHOD FOR INSTALLING AMMONIA SENSOR 3430
REMOVE AND INSTALL SCR OUTLET NOx SENSOR 3434
METHOD FOR REMOVING SCR OUTLET NOx SENSOR 3434
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR 3437
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 3442
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 3442
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 3443
60 MAINTENANCE STANDARD 3445
CONTENTS 3446
ABBREVIATION LIST 3448
ENGINE AND COOLING SYSTEM 3454
MAINTENANCE STANDARD OF ENGINE MOUNT 3454
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP 3455
MAINTENANCE STANDARD OF SERVO VALVE OF BRAKE AND COOLING FAN PUMP 3457
MAINTENANCE STANDARD OF COOLING FAN MOTOR 3458
POWER TRAIN 3460
MAINTENANCE STANDARD OF DRIVE SHAFT 3460
MAINTENANCE STANDARD OF TORQUE CONVERTER 3461
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 3463
MAINTENANCE STANDARD OF TRANSMISSION 3464
MAINTENANCE STANDARD OF F, 1ST CLUTCH 3470
MAINTENANCE STANDARD OF R, 2ND CLUTCH 3472
MAINTENANCE STANDARD OF 3RD, 4TH CLUTCH 3474
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE 3476
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND CLUTCH ECMV 3478
MAINTENANCE STANDARD OF 3RD, 4TH CLUTCH ECMV 3479
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 3480
MAINTENANCE STANDARD OF FRONT AXLE 3481
MAINTENANCE STANDARD OF REAR AXLE 3482
MAINTENANCE STANDARD OF FRONT CONVENTIONAL DIFFERENTIAL 3483
MAINTENANCE STANDARD OF REAR CONVENTIONAL DIFFERENTIAL 3486
MAINTENANCE STANDARD OF FRONT LIMITED SLIP DIFFERENTIAL 3489
MAINTENANCE STANDARD OF REAR LIMITED SLIP DIFFERENTIAL 3491
MAINTENANCE STANDARD OF FINAL DRIVE 3493
STEERING SYSTEM 3496
MAINTENANCE STANDARD OF STEERING COLUMN 3496
MAINTENANCE STANDARD OF STEERING PUMP 3497
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING PUMP 3500
MAINTENANCE STANDARD OF STEERING VALVE 3501
MAINTENANCE STANDARD OF STEERING CYLINDER 3503
MAINTENANCE STANDARD OF SECONDARY STEERING PUMP 3505
BRAKE SYSTEM 3506
MAINTENANCE STANDARD OF CHARGE VALVE 3506
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR 3508
MAINTENANCE STANDARD OF SLACK ADJUSTER 3509
MAINTENANCE STANDARD OF FRONT BRAKE 3510
MAINTENANCE STANDARD OF REAR BRAKE 3511
MAINTENANCE STANDARD OF PARKING BRAKE 3512
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE 3514
MAINTENANCE STANDARD OF FLOW PRIORITY VALVE 3515
MAINTENANCE STANDARD OF BRAKE COOLING PUMP 3516
MAINTENANCE STANDARD OF BRAKE COOLING STRAINER 3517
UNDERCARRIAGE AND FRAME 3518
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 3518
HYDRAULIC SYSTEM 3523
MAINTENANCE STANDARD OF HYDRAULIC TANK 3523
MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP 3525
MAINTENANCE STANDARD OF POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP 3527
MAINTENANCE STANDARD OF CONTROL VALVE 3528
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE 3537
WORK EQUIPMENT 3538
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 3538
MAINTENANCE STANDARD OF BUCKET 3542
MAINTENANCE STANDARD OF LIFT CYLINDER 3543
MAINTENANCE STANDARD OF BUCKET CYLINDER 3544
80 APPENDIX 3545
CONTENTS 3546
ABBREVIATION LIST 3548
AIR CONDITIONER SYSTEM 3554
PRECAUTIONS FOR REFRIGERANT 3554
AIR CONDITIONER COMPONENT 3555
SPECIFICATIONS OF AIR CONDITIONER 3557
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3558
OUTLINE OF REFRIGERATION CYCLE 3559
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3561
AIR CONDITIONER UNIT 3561
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3561
FUNCTION OF AIR CONDITIONER UNIT 3562
COMPONENT PARTS OF AIR CONDITIONER UNIT 3563
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3563
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3563
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT 3564
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT 3564
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT 3564
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3564
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3564
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3564
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3565
FUNCTION OF DUAL PRESSURE SWITCH 3565
AIR CONDITIONER CONTROLLER 3566
STRUCTURE OF AIR CONDITIONER CONTROLLER 3566
COMPRESSOR 3567
STRUCTURE OF COMPRESSOR 3567
SPECIFICATIONS OF COMPRESSOR 3567
FUNCTION OF COMPRESSOR 3567
CONDENSER 3568
STRUCTURE OF CONDENSER 3568
SPECIFICATIONS OF CONDENSER 3568
FUNCTION OF CONDENSER 3568
RECEIVER DRIER 3569
STRUCTURE OF RECEIVER DRIER 3569
SPECIFICATIONS OF RECEIVER DRIER 3569
FUNCTION OF RECEIVER DRIER 3569
SENSORS FOR AIR CONDITIONER SYSTEM 3570
FUNCTION OF SUNLIGHT SENSOR 3570
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3570
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3571
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3573
AIR CONDITIONER SYSTEM DIAGRAM 3576
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3577
FUNCTION OF AIR CONDITIONER CONTROLLER 3578
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3579
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3585
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3586
CHECK TEMPERATURE CONTROL FUNCTION 3587
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION 3587
TEST VENT (MODE) CHANGEOVER 3589
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3589
TESTING FRESH/RECIRC AIR CHANGEOVER 3591
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3591
TEST EVAPORATOR TEMPERATURE SENSOR 3593
TEST RELAYS 3595
METHOD FOR TESTING RELAYS 3595
AIR CONDITIONER TROUBLESHOOTING CHART 1 3597
AIR CONDITIONER TROUBLESHOOTING CHART 2 3598
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3601
FAILURE CODE [879AKA] 3603
FAILURE CODE [879AKB] 3605
FAILURE CODE [879BKA] 3607
FAILURE CODE [879BKB] 3609
FAILURE CODE [879CKA] 3611
FAILURE CODE [879CKB] 3613
FAILURE CODE [879DKZ] 3615
FAILURE CODE [879EMC] 3617
FAILURE CODE [879FMC] 3620
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3623
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3626
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3629
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3633
TROUBLESHOOTING USING GAUGE PRESSURE 3635
CONNECTION OF SERVICE TOOL 3638
METHOD FOR CONNECTING SERVICE TOOL 3639
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3640
HANDLE COMPRESSOR OIL 3642
90 CIRCUIT DIAGRAMS 3645
CONTENTS 3646
ABBREVIATION LIST 3647
HYDRAULIC CIRCUIT DIAGRAM 3653
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3653
HYDRAULIC CIRCUIT DIAGRAM (FOR AJSS SPEC) 3657
HYDRAULIC CIRCUIT DIAGRAM (FOR STEERING WHEEL SPEC) 3658
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 3659
HYDRAULIC OIL PRESSURE OF BRAKE COOLING SYSTEM 3661
HYDRAULIC AUTO-GREASING DIAGRAM 3663
ELECTRICAL CIRCUIT DIAGRAM 3664
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3664
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/6) 3668
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/6) 3669
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/6) 3670
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/6) 3671
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/6) 3672
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/6) 3673
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (1/9) 3674
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (2/9) 3675
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (3/9) 3676
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (4/9) 3677
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (5/9) 3678
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (6/9) 3679
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (7/9) 3680
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (8/9) 3681
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (9/9) 3682
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (1/8) 3683
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (2/8) 3684
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (3/8) 3685
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (4/8) 3686
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (5/8) 3687
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (6/8) 3688
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (7/8) 3689
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (8/8) 3690
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (1/9) 3691
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (2/9) 3692
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (3/9) 3693
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (4/9) 3694
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (5/9) 3695
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (6/9) 3696
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (7/9) 3697
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (8/9) 3698
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (9/9) 3699
INDEX 3700

DESCRIPTION:

Komatsu WA480-8 Wheel Loader Shop Manual SEN06663-01 – PDF DOWNLOAD 

SERIAL NUMBERS 100001 and up

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

S.V 29/12/24