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KOMATSU WA480-8 WHEEL LOADER SHOP MANUAL SEN06663-09 – PDF DOWNLOAD
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Description
KOMATSU WA480-8 WHEEL LOADER SHOP MANUAL SEN06663-09 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA480-8 WHEEL LOADER SHOP MANUAL SEN06663-09 – PDF DOWNLOAD
Language : English
Pages : 4338
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU WA480-8 WHEEL LOADER SHOP MANUAL SEN06663-09 – PDF DOWNLOAD
Cover........................................................................................................................................................................ 1 00 Index and Foreword................................................................................................................................................... 3 Index............................................................................................................................................................... 4 Abbreviation List................................................................................................................................................... 29 Foreword, Safety, Basic Information................................................................................................................................. 35 How to Read the Shop Manual..................................................................................................................................... 35 Safety Notice for Operation..................................................................................................................................... 37 Precautions to Prevent Fire..................................................................................................................................... 45 Procedures If Fire Occurs....................................................................................................................................... 47 Precautions for Disposing of Waste Materials.................................................................................................................... 48 Procedures for Exhaust Gas Regulations.......................................................................................................................... 49 Precautions for DEF............................................................................................................................................. 50 General Character and Precautions for Handling.............................................................................................................. 50 Precautions for Adding...................................................................................................................................... 50 Precautions for Storage..................................................................................................................................... 50 Precautions for Fire Hazard and Leakage..................................................................................................................... 50 Other Precautions........................................................................................................................................... 50 Store DEF....................................................................................................................................................... 51 Precautions When You Handle Hydraulic Equipment................................................................................................................. 52 Precautions When You Disconnect and Connect Pipings............................................................................................................. 55 Precautions When You Handle Electrical Equipment................................................................................................................ 62 Precautions When You Handle Fuel System Equipment............................................................................................................... 64 Precautions When You Handle Intake System Equipment............................................................................................................. 65 Practical Use of KOMTRAX........................................................................................................................................ 66 Disconnect and Connect Push-Pull Type Coupler................................................................................................................... 67 How to Disconnect and Connect Type 1 Push-Pull Type Coupler................................................................................................. 67 How to Disconnect and Connect Type 2 Push-Pull Type Coupler................................................................................................. 68 How to Disconnect and Connect Type 3 Push-Pull Type Coupler................................................................................................. 69 Precautions for Disconnection and Connection of Connectors...................................................................................................... 71 How to Disconnect and Connect Deutsch Connector................................................................................................................. 75 How to Disconnect and Connect Slide Lock Type Connector......................................................................................................... 76 How to Disconnect and Connect Connector with Lock to Pull....................................................................................................... 78 How to Disconnect and Connect Connector with Lock to Push....................................................................................................... 79 How to Disconnect and Connect Connector with Housing to Rotate.................................................................................................. 81 How to Read the Codes for Electric Cable........................................................................................................................ 82 Explanation of Terms for Maintenance Standard................................................................................................................... 86 Standard Tightening Torque Table................................................................................................................................ 89 Conversion Table................................................................................................................................................ 96 01 Specifications....................................................................................................................................................... 101 Table of Contents................................................................................................................................................... 102 Abbreviation List................................................................................................................................................... 103 Specifications...................................................................................................................................................... 109 Specification Drawing........................................................................................................................................... 109 Specification Drawing: WA480-8.............................................................................................................................. 109 Specifications.................................................................................................................................................. 111 Specification: WA480-8...................................................................................................................................... 111 Weight Table.................................................................................................................................................... 117 Weight Table: WA480-8....................................................................................................................................... 117 Fuel, Coolant, Lubricants (For North America)................................................................................................................... 119 How to Use Fuel, Coolant and Lubricants by Ambient Temperature.............................................................................................. 119 Fuel, Coolant, Lubricants (For European Union).................................................................................................................. 121 How to Use Fuel, Coolant and Lubricants by Ambient Temperature.............................................................................................. 121 10 Structure and Function............................................................................................................................................... 123 Table of Contents................................................................................................................................................... 124 Abbreviation List................................................................................................................................................... 129 Urea SCR System..................................................................................................................................................... 135 Layout Drawing of Urea SCR System............................................................................................................................... 135 Urea SCR System Diagram......................................................................................................................................... 137 Function of Urea SCR System..................................................................................................................................... 138 Function of DEF System...................................................................................................................................... 138 Inducement Strategy......................................................................................................................................... 141 Component Parts of Urea SCR System.............................................................................................................................. 155 DEF Mixing Tube............................................................................................................................................. 155 SCR Assembly................................................................................................................................................ 156 DEF Tank.................................................................................................................................................... 158 DEF Pump.................................................................................................................................................... 160 DEF Injector................................................................................................................................................ 161 DEF Hose.................................................................................................................................................... 162 DEF Tank Heating Valve...................................................................................................................................... 163 Boot-up System...................................................................................................................................................... 164 Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal)................................................................................................ 164 Layout Drawing of Boot-up System (Machine with Gateway Function Controller)..................................................................................... 166 System Operating Lamp System.................................................................................................................................... 168 System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal).............................................................................. 168 System Diagram of System Operating Lamp System (Machine with Gateway Function Controller)................................................................... 168 Function of System Operating Lamp System (Machine with KOMTRAX Terminal).................................................................................... 168 Function of System Operating Lamp System (Machine with Gateway Function Controller)......................................................................... 169 Battery Disconnect Switch....................................................................................................................................... 171 Function of Battery Disconnect Switch....................................................................................................................... 171 Preheating System............................................................................................................................................... 172 System Diagram of Preheating System......................................................................................................................... 172 Function of Automatic Preheating System..................................................................................................................... 172 Operation of Automatic Preheating System.................................................................................................................... 172 Function of Manual Preheating System........................................................................................................................ 173 Operation of Manual Preheating System....................................................................................................................... 173 Engine System....................................................................................................................................................... 174 Layout Drawing of Engine System................................................................................................................................. 174 Function of Engine System................................................................................................................................... 175 Engine Control System........................................................................................................................................... 176 System Diagram of Engine Control System (Machine with KOMTRAX Terminal)..................................................................................... 176 System Diagram of Engine Control System (Machine with Gateway Function Controller).......................................................................... 177 Function of Engine Control System........................................................................................................................... 177 Operation of Engine Control System.......................................................................................................................... 180 Engine Power Mode Selector System............................................................................................................................... 182 Engine Power Mode Selector System Diagram................................................................................................................... 182 Function of Engine Power Mode Selector System............................................................................................................... 182 Operation of Engine Power Mode Selector System.............................................................................................................. 182 Automatic Idle Stop System...................................................................................................................................... 184 Function of Automatic Idle Stop System...................................................................................................................... 184 Component Parts of Engine System................................................................................................................................ 185 VGT......................................................................................................................................................... 185 EGR System.................................................................................................................................................. 189 EGR Valve................................................................................................................................................... 191 EGR Cooler.................................................................................................................................................. 193 KCCV System................................................................................................................................................. 194 KCCV Ventilator............................................................................................................................................. 196 KDPF........................................................................................................................................................ 198 Cooling System...................................................................................................................................................... 202 Layout Drawing of Cooling System................................................................................................................................ 202 Specifications of Cooling System............................................................................................................................ 203 Cooling Fan Control System...................................................................................................................................... 204 System Diagram of Cooling Fan Control System................................................................................................................ 204 Function of Cooling Fan Control System...................................................................................................................... 204 Component Parts of Cooling System............................................................................................................................... 209 Brake and Cooling Fan Pump.................................................................................................................................. 209 Cooling Fan Motor........................................................................................................................................... 217 Control System...................................................................................................................................................... 223 Layout Drawing of Control System (Machine with KOMTRAX Terminal)................................................................................................ 223 Layout Drawing of Control System (Machine with Gateway Function Controller)..................................................................................... 225 Machine Monitor System.......................................................................................................................................... 227 System Diagram of Machine Monitor System.................................................................................................................... 227 Function of Machine Monitor System.......................................................................................................................... 227 Rearview Monitor System......................................................................................................................................... 229 System Diagram of Rearview Monitor System................................................................................................................... 229 Function of Rearview Monitor System......................................................................................................................... 229 KOMTRAX System.................................................................................................................................................. 230 KOMTRAX System Diagram (Machine with KOMTRAX Terminal)...................................................................................................... 230 System Diagram of KOMTRAX System (Machine with Gateway Function Controller)................................................................................. 230 Function of KOMTRAX System.................................................................................................................................. 231 Load Meter System............................................................................................................................................... 232 Load Meter System Diagram (Machine with KOMTRAX Terminal)................................................................................................... 232 Load Meter System Diagram (Machine with Gateway Function Controller)........................................................................................ 233 Function of Load Meter System............................................................................................................................... 233 Component Parts of Control System............................................................................................................................... 239 Machine Monitor............................................................................................................................................. 239 Switch Panel................................................................................................................................................ 261 Rearview Monitor............................................................................................................................................ 262 Rearview Camera............................................................................................................................................. 264 KOMTRAX Terminal............................................................................................................................................ 265 Gateway Function Controller................................................................................................................................. 267 Communication Terminal...................................................................................................................................... 270 Transmission Controller..................................................................................................................................... 272 Work Equipment Controller................................................................................................................................... 277 Monitor Controller.......................................................................................................................................... 282 CAN Terminating Resistor.................................................................................................................................... 287 Engine Controller........................................................................................................................................... 288 Accelerator Pedal........................................................................................................................................... 295 Hydraulic System.................................................................................................................................................... 297 Layout Drawing of Hydraulic System.............................................................................................................................. 297 CLSS............................................................................................................................................................ 298 Structure of CLSS........................................................................................................................................... 298 Function of CLSS............................................................................................................................................ 299 Work Equipment Pump and Steering Pump Control System............................................................................................................ 302 Swash Plate Control Function of Work Equipment Pump and Steering Pump....................................................................................... 302 Pickup Assistance Control Function When Engine Speed is Low................................................................................................. 302 Overheat Prevention Function of Work Equipment Circuit...................................................................................................... 302 Component Parts of Hydraulic System............................................................................................................................. 303 Hydraulic Tank.............................................................................................................................................. 303 Work Equipment Pump......................................................................................................................................... 306 Steering Pump............................................................................................................................................... 324 Power Train Charge Pump and Power Train Lubrication Pump.................................................................................................... 337 Control Valve............................................................................................................................................... 338 Power Train System.................................................................................................................................................. 373 Layout Drawing of Power Train System............................................................................................................................ 373 Operation of Power Train System................................................................................................................................. 376 Transmission Control System..................................................................................................................................... 377 Transmission Control System Diagram......................................................................................................................... 377 Transmission Gear Shift Control System.......................................................................................................................... 379 Electric Modulation Function System Diagram................................................................................................................. 379 Electric Modulation Function................................................................................................................................ 380 Gear Shift Display Function................................................................................................................................. 380 Automatic Gear Shift Function............................................................................................................................... 380 Shift Hold Function......................................................................................................................................... 381 Kickdown Function........................................................................................................................................... 381 Automatic Kickdown Function................................................................................................................................. 382 Torque Converter Lockup Function............................................................................................................................ 382 Hunting Prevention Function................................................................................................................................. 383 Transmission Initial Learning and ECMV Current Adjustment Function.......................................................................................... 383 Shift Point Changing Function............................................................................................................................... 383 4th Gear Speed Limitation Function.......................................................................................................................... 383 Transmission Protection Function................................................................................................................................ 385 Protection Function When Travel Direction is Changed........................................................................................................ 385 Shift Down Protection Function.............................................................................................................................. 386 Engine Overrun Prevention Function.......................................................................................................................... 386 Maximum Speed Limitation Function........................................................................................................................... 386 Neutralizer Function........................................................................................................................................ 387 Directional Selector Switch Control Function.................................................................................................................... 388 Transmission Cut-off Function................................................................................................................................... 390 Component Parts of Power Train System........................................................................................................................... 392 Drive Shaft................................................................................................................................................. 392 Torque Converter............................................................................................................................................ 394 Lockup Clutch ECMV.......................................................................................................................................... 398 Transmission................................................................................................................................................ 401 Transmission Control Valve.................................................................................................................................. 418 Forward and Reverse Clutch ECMV and 1st, 2nd Clutch ECMV.................................................................................................... 421 3rd and 4th Clutch ECMV..................................................................................................................................... 426 Main Relief Valve and Torque Converter Relief Valve......................................................................................................... 432 Axle........................................................................................................................................................ 434 Conventional Differential................................................................................................................................... 436 Limited Slip Differential................................................................................................................................... 439 Final Drive................................................................................................................................................. 444 AJSS Knob................................................................................................................................................... 446 Combination Switch.......................................................................................................................................... 447 Shift Hold Switch........................................................................................................................................... 451 Kickdown Switch............................................................................................................................................. 452 Work Equipment System............................................................................................................................................... 453 Layout Drawing of Work Equipment System......................................................................................................................... 453 Work Equipment System Diagram (Applicable Machine: 100001 to 101011)............................................................................................ 455 Work Equipment System Diagram (Applicable Machine: 101012 and Up)............................................................................................... 457 Work Equipment Control System................................................................................................................................... 459 Work Equipment Speed Pattern Control Function by Work Equipment Lever Stroke................................................................................ 459 Work Equipment Lever Detent Position and Work Equipment Startup Current Control Function.................................................................... 459 Work Equipment Lever Operating Function System Diagram...................................................................................................... 460 Work Equipment Lever Operation Function..................................................................................................................... 461 Bucket Priority Control Function............................................................................................................................ 461 Boom Stop Modulation Function............................................................................................................................... 461 Work Equipment Neutral Lock System.............................................................................................................................. 463 Work Equipment Neutral Lock System Diagram.................................................................................................................. 463 Function of Work Equipment Neutral Lock System.............................................................................................................. 463 Remote Positioner System........................................................................................................................................ 465 Remote Bucket Positioner System Diagram..................................................................................................................... 465 Function of Remote Bucket Positioner System................................................................................................................. 465 Remote Boom Positioner System Diagram....................................................................................................................... 466 Function of Remote Boom Positioner System................................................................................................................... 466 Bucket Positioner and Boom Positioner........................................................................................................................... 470 Structure of Bucket Positioner and Boom Positioner.......................................................................................................... 470 Auto-Digging System............................................................................................................................................. 471 Auto-Digging System Diagram................................................................................................................................. 471 Function of Auto-Digging System............................................................................................................................. 471 ECSS............................................................................................................................................................ 473 ECSS Diagram................................................................................................................................................ 473 Function of ECSS............................................................................................................................................ 473 Operation of ECSS........................................................................................................................................... 473 Component Parts of Work Equipment System........................................................................................................................ 475 Work Equipment Lock Solenoid Valve.......................................................................................................................... 475 Pilot Circuit Accumulator................................................................................................................................... 476 ECSS Circuit Accumulator.................................................................................................................................... 477 Work Equipment Electric Lever............................................................................................................................... 479 Multifunction Mono-Lever.................................................................................................................................... 482 Steering System..................................................................................................................................................... 483 Layout Drawing of Steering System............................................................................................................................... 483 Secondary Steering System....................................................................................................................................... 486 Secondary Steering System Diagram........................................................................................................................... 486 Function of Secondary Steering System....................................................................................................................... 486 AJSS............................................................................................................................................................ 488 Layout Drawing of AJSS...................................................................................................................................... 488 AJSS System Diagram......................................................................................................................................... 489 Function of AJSS............................................................................................................................................ 490 Neutralizer Function of AJSS................................................................................................................................ 491 AJSS Neutral Interlock Function............................................................................................................................. 491 AJSS Speed Sensing Steering Function........................................................................................................................ 492 AJSS Turn Signal Pilot Lamp Control Function................................................................................................................ 493 Steering Column................................................................................................................................................. 494 Structure of Steering Column................................................................................................................................ 494 Component Parts of Steering System.............................................................................................................................. 495 AJSS EPC Valve.............................................................................................................................................. 495 Steering Lock Valve......................................................................................................................................... 496 Rotary Valve................................................................................................................................................ 497 Orbitrol Valve.............................................................................................................................................. 500 Stop Valve.................................................................................................................................................. 504 Steering Valve.............................................................................................................................................. 505 Secondary Steering Pump..................................................................................................................................... 517 Secondary Steering Motor.................................................................................................................................... 518 Brake System........................................................................................................................................................ 519 Layout Drawing of Brake System.................................................................................................................................. 519 Layout Drawing of Brake Cooling System...................................................................................................................... 521 Parking Brake Control System.................................................................................................................................... 524 System Diagram of Parking Brake Control System.............................................................................................................. 524 Operation of Parking Brake Control System................................................................................................................... 524 Brake Cooling Control System.................................................................................................................................... 526 Brake Cooling Control System Diagram........................................................................................................................ 526 Function of Brake Cooling Control System.................................................................................................................... 528 Component Parts of Brake System................................................................................................................................. 529 Charge Valve................................................................................................................................................ 529 Parking Brake Solenoid Valve................................................................................................................................ 534 Parking Brake Emergency Release Valve....................................................................................................................... 536 Brake Circuit Accumulator................................................................................................................................... 537 Brake Valve................................................................................................................................................. 539 Slack Adjuster.............................................................................................................................................. 543 Brake....................................................................................................................................................... 545 Parking Brake............................................................................................................................................... 548 Flow Priority Valve......................................................................................................................................... 550 Brake Cooling Motor......................................................................................................................................... 552 Brake Cooling Pump.......................................................................................................................................... 553 Brake Cooling Pump Motor.................................................................................................................................... 554 Brake Cooling Oil Cooler.................................................................................................................................... 555 Brake Cooling Fan........................................................................................................................................... 558 Manual Type Valve........................................................................................................................................... 559 Auto-Greasing System................................................................................................................................................ 560 Layout Drawing of Auto-Greasing System.......................................................................................................................... 560 Specifications of Auto-Greasing System.......................................................................................................................... 561 Function of Auto-Greasing System................................................................................................................................ 563 Auto-Greasing System............................................................................................................................................ 564 Auto-Greasing Pump.......................................................................................................................................... 564 Undercarriage and Frame............................................................................................................................................. 565 Frame, Axle Mount and Center Hinge Pin.......................................................................................................................... 565 Structure of Frame, Axle Mount and Center Hinge Pin......................................................................................................... 565 Function of Frame, Axle Mount and Center Hinge Pin.......................................................................................................... 565 Tires........................................................................................................................................................... 567 Features of Radial Tire When Compared with Bias Tire........................................................................................................ 567 Structure of Radial Tire.................................................................................................................................... 567 Function of Radial Tire..................................................................................................................................... 568 Structure of Bias Tire...................................................................................................................................... 568 Function of Bias Tire....................................................................................................................................... 568 Work Equipment...................................................................................................................................................... 569 Structure of Work Equipment..................................................................................................................................... 569 Structure of Bucket............................................................................................................................................. 570 CAB Related Parts................................................................................................................................................... 571 ROPS CAB........................................................................................................................................................ 571 Structure of ROPS CAB (Machine with KOMTRAX Terminal)....................................................................................................... 571 Structure of ROPS CAB (Machine with Gateway Function Controller)............................................................................................ 572 Function of ROPS CAB........................................................................................................................................ 572 20 Standard Value Table................................................................................................................................................. 573 Table of Contents................................................................................................................................................... 574 Abbreviation List................................................................................................................................................... 575 Standard Value Table for Engine..................................................................................................................................... 581 Standard Value Table for Engine: WA480-8........................................................................................................................ 581 Standard Value Table for Machine.................................................................................................................................... 585 Standard Value Table for Machine: WA480-8....................................................................................................................... 585 Machine Posture and Procedures to Measure Performance........................................................................................................... 610 30 Testing and Adjusting................................................................................................................................................ 615 Table of Contents................................................................................................................................................... 616 Precautions Before Work............................................................................................................................................. 620 Abbreviation List................................................................................................................................................... 621 Related Information on Testing and Adjusting........................................................................................................................ 627 Differences In Machine Monitor Symbols.......................................................................................................................... 627 Tools for Testing and Adjusting................................................................................................................................. 628 Sketch of Tools for Testing and Adjusting....................................................................................................................... 638 Engine and Cooling System........................................................................................................................................... 640 Examine Engine Speed............................................................................................................................................ 640 How to Examine Engine Speed................................................................................................................................. 640 Examine Boost Pressure.......................................................................................................................................... 645 How to Examine Boost Pressure............................................................................................................................... 645 Examine Exhaust Gas Temperature................................................................................................................................. 648 How to Examine Exhaust Gas Temperature...................................................................................................................... 648 Examine Exhaust Gas Color....................................................................................................................................... 650 How to Examine Exhaust Gas Color with the Handy Smoke Checker............................................................................................... 650 How to Examine Exhaust Gas Color with Smoke Meter........................................................................................................... 651 Examine Mass Air Flow and Temperature Sensor.................................................................................................................... 653 How to Examine Mass Air Flow and Temperature Sensor......................................................................................................... 653 Examine and Adjust Valve Clearance.............................................................................................................................. 655 How to Examine Valve Clearance.............................................................................................................................. 655 How to Adjust Valve Clearance............................................................................................................................... 657 Examine Compression Pressure.................................................................................................................................... 658 How to Examine Compression Pressure......................................................................................................................... 658 Examine Blowby Pressure......................................................................................................................................... 662 How to Examine Blowby Pressure.............................................................................................................................. 662 Examine Engine Oil Pressure..................................................................................................................................... 665 How to Examine Engine Oil Pressure on Machine Monitor....................................................................................................... 665 How to Examine Engine Oil Pressure by Testing Tool.......................................................................................................... 665 Examine EGR Valve and VGT Oil Pressure.......................................................................................................................... 667 How to Examine EGR Valve and VGT Oil Pressure............................................................................................................... 667 Examine Fuel Pressure........................................................................................................................................... 668 How to Examine Fuel Pressure................................................................................................................................ 668 Examine Fuel Return Rate and Leakage............................................................................................................................ 670 How to Examine Fuel Return Rate and Leakage................................................................................................................. 671 Bleed Air from Fuel System...................................................................................................................................... 674 How to Bleed Air from Fuel System........................................................................................................................... 675 Examine Fuel Circuit for Leakage................................................................................................................................ 676 How to Examine Fuel System for Leakage...................................................................................................................... 676 Handle Cylinder Cut-out Mode Operation.......................................................................................................................... 678 Handle No-Injection Cranking Operation.......................................................................................................................... 679 Examine KDPF, SCR and Muffler Stack for Looseness and Damage.................................................................................................... 680 How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage......................................................................................... 680 Examine Installed Condition of Cylinder Heads and Manifolds..................................................................................................... 681 How to Examine Installed Condition of Cylinder Heads and Manifolds.......................................................................................... 681 Examine Engine Piping for Damage and Looseness.................................................................................................................. 682 How to Examine Engine Piping for Damage and Looseness....................................................................................................... 682 Examine and Adjust Air Conditioner Compressor Belt Tension...................................................................................................... 683 How to Examine Air Conditioner Compressor Belt Tension...................................................................................................... 683 How to Adjust Air Conditioner Compressor Belt Tension....................................................................................................... 683 Examine Alternator Belt......................................................................................................................................... 685 How to Examine Alternator Belt.............................................................................................................................. 685 Examine Automatic Tensioner..................................................................................................................................... 687 How to Examine Automatic Tensioner.......................................................................................................................... 687 Clean Fuel Doser................................................................................................................................................ 690 How to Clean Fuel Doser..................................................................................................................................... 690 Write Injector Compensation Value to Engine Controller.......................................................................................................... 692 How to Write Injector Compensation Value.................................................................................................................... 692 Write Correction for Ash in Soot Accumulation to Engine Controller.............................................................................................. 699 How to Write Correction for Ash in Soot Accumulation to Engine Controller................................................................................... 699 Examine SCR Related Functions................................................................................................................................... 700 Examine DEF Pump Raised Pressure............................................................................................................................ 704 Examine Injection Volume from DEF Injector.................................................................................................................. 707 Examine DEF Line Heater Relay 1............................................................................................................................. 712 Examine DEF Line Heater Relay 2............................................................................................................................. 716 Examine DEF Pump Heater Relay............................................................................................................................... 720 Examine DEF Tank Heater Valve............................................................................................................................... 724 Examine SCR Denitration Efficiency.......................................................................................................................... 728 Clean DEF Tank.................................................................................................................................................. 732 How to Clean DEF Tank....................................................................................................................................... 732 Clean DEF Pump.................................................................................................................................................. 736 How to Clean DEF Pump....................................................................................................................................... 736 Power Train......................................................................................................................................................... 742 Examine and Adjust Power Train Oil Pressure..................................................................................................................... 742 How to Examine Power Train Oil Pressure..................................................................................................................... 744 How to Adjust Power Train Oil Pressure...................................................................................................................... 762 Adjust Transmission Input Shaft Speed Sensor.................................................................................................................... 764 How to Adjust Transmission Input Shaft Speed Sensor......................................................................................................... 764 Adjust Transmission Output Shaft Speed Sensor................................................................................................................... 766 How to Adjust Transmission Output Shaft Speed Sensor........................................................................................................ 766 Flush Torque Converter and Transmission Hydraulic Circuit....................................................................................................... 767 How to Flush Torque Converter and Transmission Hydraulic Circuit............................................................................................ 767 Move Disabled Machine Due to Transmission Valve Failure......................................................................................................... 770 How to Move Disabled Machine Due to Transmission Valve Failure.............................................................................................. 771 Examine Drive Shaft for Looseness, Backlash, and Damage......................................................................................................... 774 How to Examine Drive Shaft for Looseness, Backlash, and Damage.............................................................................................. 774 Steering System..................................................................................................................................................... 775 Examine Steering Wheel.......................................................................................................................................... 775 How to Examine Steering Wheel............................................................................................................................... 775 Examine and Adjust Steering Circuit Oil Pressure................................................................................................................ 777 How to Examine Steering Circuit Oil Pressure................................................................................................................ 777 How to Adjust Steering Circuit Oil Pressure................................................................................................................. 781 Bleed Air from Steering Cylinder Circuit........................................................................................................................ 783 How to Bleed Air from Steering Cylinder Circuit............................................................................................................. 783 Examine and Adjust Steering Stop Valve.......................................................................................................................... 785 How to Examine Steering Stop Valve.......................................................................................................................... 785 How to Adjust Steering Stop Valve........................................................................................................................... 785 Brake System........................................................................................................................................................ 786 Release Remained Pressure in Brake Accumulator Circuit.......................................................................................................... 786 How to Release Remained Pressure in Brake Accumulator Circuit............................................................................................... 786 Examine Wheel Brake Oil Pressure................................................................................................................................ 787 How to Examine Wheel Brake Oil Pressure..................................................................................................................... 787 Examine and Adjust Accumulator Charge Pressure.................................................................................................................. 789 How to Examine Accumulator Charge Pressure.................................................................................................................. 789 How to Adjust Accumulator Charge Pressure................................................................................................................... 790 Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas............................................................................................... 791 How to Examine Accumulator Nitrogen Gas Pressure for Brake.................................................................................................. 791 How to Charge Accumulator Nitrogen Gas for Brake............................................................................................................ 794 How to Release Nitrogen Gas When You Discard Accumulator.................................................................................................... 798 Bleed Air from Brake Circuit.................................................................................................................................... 800 How to Bleed Air from Brake Circuit......................................................................................................................... 800 Examine Brake Performance....................................................................................................................................... 804 How to Examine Brake Performance............................................................................................................................ 804 Examine Brake Pedal............................................................................................................................................. 805 How to Examine Brake Pedal.................................................................................................................................. 805 Examine and Adjust Brake Pedal and Linkage...................................................................................................................... 806 How to Examine Brake Pedal and Linkage...................................................................................................................... 806 How to Adjust Brake Pedal and Linkage....................................................................................................................... 806 Examine Pressure Decrease of Wheel Brake........................................................................................................................ 807 How to Examine Pressure Decrease of Wheel Brake............................................................................................................. 808 Examine Wear of Wheel Brake Disc................................................................................................................................ 810 How to Examine Wear of Wheel Brake Disc..................................................................................................................... 810 Examine Parking Brake Oil Pressure.............................................................................................................................. 812 How to Examine Parking Brake Oil Pressure................................................................................................................... 812 Examine Parking Brake Performance............................................................................................................................... 814 How to Examine Parking Brake Performance.................................................................................................................... 814 Release Parking Brake Manually.................................................................................................................................. 815 How to Release Parking Brake Manually....................................................................................................................... 815 Examine Wear Volume of Parking Brake Disc....................................................................................................................... 818 How to Examine Wear Quantity of Parking Brake Disc.......................................................................................................... 818 Hydraulic System.................................................................................................................................................... 820 Release Remained Pressure from Work Equipment Circuit........................................................................................................... 820 How to Release Remained Pressure from Work Equipment Circuit................................................................................................ 820 Examine and Adjust Work Equipment Oil Pressure.................................................................................................................. 822 How to Examine Work Equipment Oil Pressure.................................................................................................................. 822 How to Adjust Work Equipment Oil Pressure................................................................................................................... 826 Examine and Adjust Work Equipment EPC Oil Pressure.............................................................................................................. 828 How to Examine Work Equipment EPC Oil Pressure.............................................................................................................. 828 How to Adjust Work Equipment EPC Oil Pressure............................................................................................................... 831 Bleed Air from Work Equipment Circuit........................................................................................................................... 833 How to Bleed Air from Work Equipment Circuit................................................................................................................ 833 Examine Cooling Fan Speed....................................................................................................................................... 834 How to Examine Cooling Fan Speed............................................................................................................................ 834 Examine Cooling Fan Circuit Oil Pressure........................................................................................................................ 835 How to Examine Cooling Fan Circuit Oil Pressure............................................................................................................. 835 Bleed Air from Cooling Fan Circuit.............................................................................................................................. 838 How to Bleed Air from Cooling Fan Circuit................................................................................................................... 838 Examine ECSS Accumulator Nitrogen Gas Pressure and Charge Accumulator with Nitrogen Gas......................................................................... 840 How to Examine ECSS Accumulator Nitrogen Gas Pressure....................................................................................................... 840 How to Charge ECSS Accumulator with Nitrogen Gas............................................................................................................ 842 Work Equipment...................................................................................................................................................... 846 Examine and Adjust Bucket Potentiometer Lever................................................................................................................... 846 How to Examine Bucket Potentiometer Lever................................................................................................................... 846 How to Adjust Bucket Potentiometer Lever.................................................................................................................... 846 Examine and Adjust Boom Potentiometer Lever..................................................................................................................... 848 How to Examine Boom Potentiometer Lever..................................................................................................................... 848 How to Adjust Boom Potentiometer Lever...................................................................................................................... 848 CAB Related Parts................................................................................................................................................... 849 Examine Directional Lever....................................................................................................................................... 849 How to Examine Directional Lever............................................................................................................................ 849 Examine Work Equipment Control Lever............................................................................................................................ 850 How to Examine Work Equipment Control Lever................................................................................................................. 850 Examine AJSS Lever (For AJSS Spec).............................................................................................................................. 853 How to Examine AJSS Lever................................................................................................................................... 853 Examine Steering Lock Lever (AJSS Specification)................................................................................................................ 856 How to Examine Steering Lock Lever.......................................................................................................................... 856 Examine and Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor (AJSS Specifications).................................................................... 857 How to Examine AJSS Lever Angle Sensor and AJSS Frame Angle Sensor.......................................................................................... 857 How to Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor........................................................................................... 857 Examine and Adjust Steering Stopper Bolt (For AJSS Spec)........................................................................................................ 859 How to Examine Steering Stopper Bolt........................................................................................................................ 859 How to Adjust Steering Stopper Bolt......................................................................................................................... 859 Adjust Play of Operator Seat.................................................................................................................................... 861 How to Adjust Play of Operator Seat......................................................................................................................... 861 Electrical System................................................................................................................................................... 862 Set and Adjust Each Equipment................................................................................................................................... 862 Prepare for Transmission ECMV Current Adjustment............................................................................................................ 865 How to Adjust Transmission ECMV Current..................................................................................................................... 866 How to Set and Reset Transmission Initial Learning.......................................................................................................... 869 Set and Operate Machine Monitor................................................................................................................................. 874 Operator Mode............................................................................................................................................... 878 Function to Show Technician Identification Status Screen.................................................................................................... 878 Function to Show Operator Identification Input Screen....................................................................................................... 878 Examine Function by LCD (Liquid Crystal Display)............................................................................................................ 879 Examine Function of Service Meter and Odometer.............................................................................................................. 880 How to Set Usage Limitation and Change Maintenance Password................................................................................................. 880 Service Mode................................................................................................................................................ 884 How to Operate Service Mode................................................................................................................................. 884 How to See Pre-defined Monitoring Information............................................................................................................... 887 How to Examine Self-Define Monitor Information.............................................................................................................. 902 Abnormality Record Menu..................................................................................................................................... 918 How to See Maintenance Record............................................................................................................................... 923 Maintenance Mode Setting.................................................................................................................................... 925 How to Set Phone Number Entry............................................................................................................................... 930 Default Menu................................................................................................................................................ 932 Diagnostic Tests Menu....................................................................................................................................... 948 Adjustment Menu............................................................................................................................................. 959 No-Injection Cranking Operation............................................................................................................................. 996 KOMTRAX Settings Menu....................................................................................................................................... 999 How to Show Service Message.................................................................................................................................1004 How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal)................................................................................................1006 How to Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal).............................................................................................1010 How to Start Up KOMTRAX System (Machine with Gateway Function Controller).......................................................................................1012 How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller)....................................................................................1018 Adjust Rearview Camera Angle....................................................................................................................................1020 How to Adjust Rearview Camera Angle.........................................................................................................................1020 Set Region of Bluetooth(R) Compatible Radio.....................................................................................................................1022 How to Set Region of Bluetooth(R) Compatible Radio..........................................................................................................1022 Handle Voltage Circuit of Engine Controller.....................................................................................................................1024 Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal)................................................................................................1025 Handle Battery Disconnect Switch (Machine with Gateway Function Controller).....................................................................................1026 Examine Diodes..................................................................................................................................................1027 How to Examine Diodes by Digital Tester.....................................................................................................................1027 How to Examine Diodes by Analog Tester......................................................................................................................1027 Auto-Greasing Device................................................................................................................................................1028 Bleed the Air in Auto-Greasing System...........................................................................................................................1028 How to Bleed the Air in Auto-Greasing System................................................................................................................1028 Correspondence in Case of Grease Leakage from over Pressure Protection Valve....................................................................................1031 Correspondence in Case of Grease Leakage from over Pressure Protection Valve................................................................................1031 Change Lubrication Time and Lubrication Interval................................................................................................................1032 How to Change Lubrication Time and Lubrication Interval.....................................................................................................1033 Examine and Fill Auto-Greasing..................................................................................................................................1035 How to Examine Auto-Greasing................................................................................................................................1035 How to Fill Auto-Greasing...................................................................................................................................1036 Pm Clinic...........................................................................................................................................................1037 Pm Clinic Service...............................................................................................................................................1037 Pm Clinic Check Sheet: WA480-8..............................................................................................................................1040 40 Troubleshooting......................................................................................................................................................1051 Table of Contents...................................................................................................................................................1052 Precautions Before Work.............................................................................................................................................1067 Abbreviation List...................................................................................................................................................1068 Related Information to Troubleshooting..............................................................................................................................1074 General Troubleshooting Points..................................................................................................................................1074 Troubleshooting Points for Urea SCR System......................................................................................................................1075 Sequence of Events in Troubleshooting...........................................................................................................................1089 Checks Before Troubleshooting...................................................................................................................................1091 Inspection Procedure Before Troubleshooting.....................................................................................................................1093 Walk-Around Check...........................................................................................................................................1093 Test in Accordance with Testing Procedure.......................................................................................................................1095 Examine Fuel Level and Type.................................................................................................................................1095 Examine for Impure Ingredient in Fuel.......................................................................................................................1095 Examine DEF Level and Type..................................................................................................................................1096 Examine Fuel Prefilter......................................................................................................................................1096 Examine Fuel Main Filter....................................................................................................................................1098 Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type.................................................................................................1099 Examine Coolant Level (Reservoir Tank)......................................................................................................................1099 Examine Air Cleaner Clogging................................................................................................................................1100 Clean Outer Element.........................................................................................................................................1101 Replace Element.............................................................................................................................................1103 Examine Hydraulic Oil Level.................................................................................................................................1104 Examine Hydraulic Oil Strainer..............................................................................................................................1105 Examine Hydraulic Oil Filter................................................................................................................................1106 Examine Oil Level in Transmission Case......................................................................................................................1107 Examine Oil Level in Front Axle Case........................................................................................................................1109 Examine Oil Level in Rear Axle Case.........................................................................................................................1110 Bleed Air from Fuel System..................................................................................................................................1110 Bleed Air from Hydraulic System.............................................................................................................................1110 How to Examine Electric Equipment...........................................................................................................................1110 Preparation for Troubleshooting of Electrical System............................................................................................................1117 Procedure for Troubleshooting...................................................................................................................................1130 Symptom and Troubleshooting Numbers.............................................................................................................................1132 Information Shown in Troubleshooting Table......................................................................................................................1137 Connector List and Layout (Machine with KOMTRAX Terminal).......................................................................................................1139 Connector List and Layout (Machine with Gateway Function Controller)............................................................................................1166 Connector Contact Connection Table..............................................................................................................................1195 T-Branch Box and T-Branch Adapter Table.........................................................................................................................1235 Fuse Location Table (Machine with KOMTRAX Terminal).............................................................................................................1241 Fuse Location Table (Machine with Gateway Function Controller)..................................................................................................1245 Precautions When You Clean and Replace KDPF (KCSF and KDOC).....................................................................................................1249 Prepare Troubleshoot Machine Monitor............................................................................................................................1253 Procedure to Make Harness Checker on Machine Monitor LCD Unit...................................................................................................1255 Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])............................................................................1261 Failure Code Table..............................................................................................................................................1263 Troubleshooting by Failure Code (Display of Code)...................................................................................................................1288 Failure Code [1500L0]...........................................................................................................................................1288 Failure Code [15SAL1]...........................................................................................................................................1289 Failure Code [15SALH]...........................................................................................................................................1291 Failure Code [15SBL1]...........................................................................................................................................1293 Failure Code [15SBLH]...........................................................................................................................................1295 Failure Code [15SEL1]...........................................................................................................................................1297 Failure Code [15SELH]...........................................................................................................................................1299 Failure Code [15SFL1]...........................................................................................................................................1301 Failure Code [15SFLH]...........................................................................................................................................1303 Failure Code [15SGL1]...........................................................................................................................................1305 Failure Code [15SGLH]...........................................................................................................................................1307 Failure Code [15SHL1]...........................................................................................................................................1309 Failure Code [15SHLH]...........................................................................................................................................1311 Failure Code [2F00MA]...........................................................................................................................................1314 Failure Code [2F00MB]...........................................................................................................................................1318 Failure Code [2G42ZG]...........................................................................................................................................1321 Failure Code [2G43ZG]...........................................................................................................................................1323 Failure Code [879AKA]...........................................................................................................................................1325 Failure Code [879AKB]...........................................................................................................................................1327 Failure Code [879BKA]...........................................................................................................................................1329 Failure Code [879BKB]...........................................................................................................................................1331 Failure Code [879CKA]...........................................................................................................................................1333 Failure Code [879CKB]...........................................................................................................................................1335 Failure Code [879DKZ]...........................................................................................................................................1337 Failure Code [879EMC]...........................................................................................................................................1339 Failure Code [879FMC]...........................................................................................................................................1342 Failure Code [989A00]...........................................................................................................................................1345 Failure Code [989L00]...........................................................................................................................................1346 Failure Code [989M00]...........................................................................................................................................1347 Failure Code [989N00]...........................................................................................................................................1348 Failure Code [A1U0N3]...........................................................................................................................................1349 Failure Code [A1U0N4]...........................................................................................................................................1351 Failure Code [AA10NX]...........................................................................................................................................1353 Failure Code [AB00KE]...........................................................................................................................................1355 Failure Code [AB00KY]...........................................................................................................................................1357 Failure Code [AQ10N3]...........................................................................................................................................1359 Failure Code [AS00N3]...........................................................................................................................................1361 Failure Code [AS00R2]...........................................................................................................................................1363 Failure Code [AS00R3]...........................................................................................................................................1364 Failure Code [AS00R4]...........................................................................................................................................1365 Failure Code [AS00R5]...........................................................................................................................................1366 Failure Code [AS00R6]...........................................................................................................................................1367 Failure Code [AS00ZK]...........................................................................................................................................1368 Failure Code [AS10KM]...........................................................................................................................................1369 Failure Code [AS10NR]...........................................................................................................................................1370 Failure Code [AS10NT]...........................................................................................................................................1371 Failure Code [B@BAZG]...........................................................................................................................................1372 Failure Code [B@BAZK]...........................................................................................................................................1373 Failure Code [B@BCNS]...........................................................................................................................................1375 Failure Code [B@BCQA]...........................................................................................................................................1376 Failure Code [B@BCZK]...........................................................................................................................................1378 Failure Code [B@C7NS]...........................................................................................................................................1380 Failure Code [B@CENS]...........................................................................................................................................1382 Failure Code [B@HANS]...........................................................................................................................................1383 Failure Code [CA115]............................................................................................................................................1384 Failure Code [CA122]............................................................................................................................................1385 Failure Code [CA123]............................................................................................................................................1387 Failure Code [CA131]............................................................................................................................................1389 Failure Code [CA132]............................................................................................................................................1391 Failure Code [CA135]............................................................................................................................................1394 Failure Code [CA141]............................................................................................................................................1396 Failure Code [CA144]............................................................................................................................................1398 Failure Code [CA145]............................................................................................................................................1400 Failure Code [CA153]............................................................................................................................................1402 Failure Code [CA154]............................................................................................................................................1405 Failure Code [CA187]............................................................................................................................................1408 Failure Code [CA221]............................................................................................................................................1410 Failure Code [CA222]............................................................................................................................................1412 Failure Code [CA227]............................................................................................................................................1414 Failure Code [CA234]............................................................................................................................................1415 Failure Code [CA238]............................................................................................................................................1416 Failure Code [CA239]............................................................................................................................................1418 Failure Code [CA249]............................................................................................................................................1420 Failure Code [CA256]............................................................................................................................................1422 Failure Code [CA271]............................................................................................................................................1424 Failure Code [CA272]............................................................................................................................................1426 Failure Code [CA273]............................................................................................................................................1427 Failure Code [CA274]............................................................................................................................................1429 Failure Code [CA322]............................................................................................................................................1430 Failure Code [CA323]............................................................................................................................................1432 Failure Code [CA324]............................................................................................................................................1434 Failure Code [CA325]............................................................................................................................................1436 Failure Code [CA331]............................................................................................................................................1438 Failure Code [CA332]............................................................................................................................................1440 Failure Code [CA343]............................................................................................................................................1442 Failure Code [CA351]............................................................................................................................................1443 Failure Code [CA352]............................................................................................................................................1444 Failure Code [CA356]............................................................................................................................................1447 Failure Code [CA357]............................................................................................................................................1449 Failure Code [CA386]............................................................................................................................................1451 Failure Code [CA431]............................................................................................................................................1452 Failure Code [CA432]............................................................................................................................................1455 Failure Code [CA441]............................................................................................................................................1459 Failure Code [CA442]............................................................................................................................................1461 Failure Code [CA449]............................................................................................................................................1462 Failure Code [CA451]............................................................................................................................................1463 Failure Code [CA452]............................................................................................................................................1465 Failure Code [CA515]............................................................................................................................................1467 Failure Code [CA516]............................................................................................................................................1469 Failure Code [CA553]............................................................................................................................................1471 Failure Code [CA555]............................................................................................................................................1472 Failure Code [CA556]............................................................................................................................................1473 Failure Code [CA559]............................................................................................................................................1474 Failure Code [CA595]............................................................................................................................................1479 Failure Code [CA687]............................................................................................................................................1480 Failure Code [CA689]............................................................................................................................................1482 Failure Code [CA691]............................................................................................................................................1484 Failure Code [CA692]............................................................................................................................................1486 Failure Code [CA697]............................................................................................................................................1488 Failure Code [CA698]............................................................................................................................................1489 Failure Code [CA731]............................................................................................................................................1490 Failure Code [CA778]............................................................................................................................................1491 Failure Code [CA1117]...........................................................................................................................................1494 Failure Code [CA1664]...........................................................................................................................................1495 Failure Code [CA1669]...........................................................................................................................................1498 Failure Code [CA1673]...........................................................................................................................................1499 Failure Code [CA1677]...........................................................................................................................................1500 Failure Code [CA1678]...........................................................................................................................................1501 Failure Code [CA1682]...........................................................................................................................................1502 Failure Code [CA1683]...........................................................................................................................................1506 Failure Code [CA1684]...........................................................................................................................................1508 Failure Code [CA1686]...........................................................................................................................................1510 Failure Code [CA1691]...........................................................................................................................................1511 Failure Code [CA1694]...........................................................................................................................................1514 Failure Code [CA1695]...........................................................................................................................................1516 Failure Code [CA1696]...........................................................................................................................................1517 Failure Code [CA1712]...........................................................................................................................................1519 Failure Code [CA1713]...........................................................................................................................................1522 Failure Code [CA1714]...........................................................................................................................................1524 Failure Code [CA1715]...........................................................................................................................................1525 Failure Code [CA1776]...........................................................................................................................................1526 Failure Code [CA1777]...........................................................................................................................................1529 Failure Code [CA1843]...........................................................................................................................................1532 Failure Code [CA1844]...........................................................................................................................................1534 Failure Code [CA1879]...........................................................................................................................................1537 Failure Code [CA1881]...........................................................................................................................................1540 Failure Code [CA1883]...........................................................................................................................................1542 Failure Code [CA1885]...........................................................................................................................................1546 Failure Code [CA1887]...........................................................................................................................................1548 Failure Code [CA1921]...........................................................................................................................................1550 Failure Code [CA1922]...........................................................................................................................................1553 Failure Code [CA1923]...........................................................................................................................................1558 Failure Code [CA1924]...........................................................................................................................................1560 Failure Code [CA1925]...........................................................................................................................................1562 Failure Code [CA1927]...........................................................................................................................................1564 Failure Code [CA1928]...........................................................................................................................................1566 Failure Code [CA1942]...........................................................................................................................................1568 Failure Code [CA1963]...........................................................................................................................................1569 Failure Code [CA1977]...........................................................................................................................................1573 Failure Code [CA1993]...........................................................................................................................................1576 Failure Code [CA2185]...........................................................................................................................................1579 Failure Code [CA2186]...........................................................................................................................................1581 Failure Code [CA2249]...........................................................................................................................................1583 Failure Code [CA2265]...........................................................................................................................................1584 Failure Code [CA2266]...........................................................................................................................................1586 Failure Code [CA2271]...........................................................................................................................................1589 Failure Code [CA2272]...........................................................................................................................................1591 Failure Code [CA2349]...........................................................................................................................................1593 Failure Code [CA2353]...........................................................................................................................................1595 Failure Code [CA2357]...........................................................................................................................................1597 Failure Code [CA2381]...........................................................................................................................................1598 Failure Code [CA2382]...........................................................................................................................................1600 Failure Code [CA2383]...........................................................................................................................................1602 Failure Code [CA2386]...........................................................................................................................................1604 Failure Code [CA2387]...........................................................................................................................................1606 Troubleshooting Flowchart...................................................................................................................................1610 Failure Code [CA2555]...........................................................................................................................................1611 Failure Code [CA2556]...........................................................................................................................................1613 Failure Code [CA2637]...........................................................................................................................................1615 Failure Code [CA2639]...........................................................................................................................................1617 Failure Code [CA2732]...........................................................................................................................................1620 Failure Code [CA2733]...........................................................................................................................................1622 Failure Code [CA2741]...........................................................................................................................................1624 Failure Code [CA2765]...........................................................................................................................................1625 Failure Code [CA2771]...........................................................................................................................................1626 Failure Code [CA2777]...........................................................................................................................................1632 Failure Code [CA2878]...........................................................................................................................................1635 Failure Code [CA2881]...........................................................................................................................................1638 Failure Code [CA2976]...........................................................................................................................................1641 Failure Code [CA3133]...........................................................................................................................................1643 Failure Code [CA3134]...........................................................................................................................................1645 Failure Code [CA3135]...........................................................................................................................................1647 Failure Code [CA3142]...........................................................................................................................................1651 Failure Code [CA3143]...........................................................................................................................................1652 Failure Code [CA3144]...........................................................................................................................................1653 Failure Code [CA3146]...........................................................................................................................................1655 Failure Code [CA3147]...........................................................................................................................................1656 Failure Code [CA3148]...........................................................................................................................................1657 Failure Code [CA3151]...........................................................................................................................................1659 Failure Code [CA3165]...........................................................................................................................................1665 Failure Code [CA3167]...........................................................................................................................................1667 Failure Code [CA3229]...........................................................................................................................................1670 Failure Code [CA3231]...........................................................................................................................................1672 Failure Code [CA3232]...........................................................................................................................................1674 Failure Code [CA3235]...........................................................................................................................................1678 Failure Code [CA3239]...........................................................................................................................................1680 Failure Code [CA3241]...........................................................................................................................................1683 Failure Code [CA3242]...........................................................................................................................................1686 Failure Code [CA3251]...........................................................................................................................................1689 Failure Code [CA3253]...........................................................................................................................................1691 Failure Code [CA3254]...........................................................................................................................................1694 Failure Code [CA3255]...........................................................................................................................................1697 Failure Code [CA3256]...........................................................................................................................................1701 Failure Code [CA3311]...........................................................................................................................................1703 Failure Code [CA3312]...........................................................................................................................................1705 Failure Code [CA3313]...........................................................................................................................................1708 Failure Code [CA3314]...........................................................................................................................................1709 Failure Code [CA3315]...........................................................................................................................................1710 Failure Code [CA3316]...........................................................................................................................................1713 Failure Code [CA3317]...........................................................................................................................................1714 Failure Code [CA3318]...........................................................................................................................................1715 Failure Code [CA3319]...........................................................................................................................................1718 Failure Code [CA3321]...........................................................................................................................................1719 Failure Code [CA3322]...........................................................................................................................................1721 Failure Code [CA3419]...........................................................................................................................................1724 Failure Code [CA3421]...........................................................................................................................................1726 Failure Code [CA3497]...........................................................................................................................................1728 Failure Code [CA3498]...........................................................................................................................................1729 Failure Code [CA3543]...........................................................................................................................................1730 Failure Code [CA3545]...........................................................................................................................................1737 Failure Code [CA3547]...........................................................................................................................................1739 Failure Code [CA3558]...........................................................................................................................................1740 Failure Code [CA3559]...........................................................................................................................................1742 Failure Code [CA3562]...........................................................................................................................................1744 Failure Code [CA3563]...........................................................................................................................................1746 Failure Code [CA3567]...........................................................................................................................................1749 Failure Code [CA3568]...........................................................................................................................................1752 Failure Code [CA3571]...........................................................................................................................................1758 Failure Code [CA3572]...........................................................................................................................................1760 Failure Code [CA3574]...........................................................................................................................................1762 Failure Code [CA3575]...........................................................................................................................................1764 Failure Code [CA3577]...........................................................................................................................................1766 Failure Code [CA3578]...........................................................................................................................................1768 Failure Code [CA3582]...........................................................................................................................................1770 Failure Code [CA3583]...........................................................................................................................................1778 Failure Code [CA3596]...........................................................................................................................................1780 Failure Code [CA3649]...........................................................................................................................................1783 Failure Code [CA3681]...........................................................................................................................................1785 Failure Code [CA3682]...........................................................................................................................................1790 Failure Code [CA3713]...........................................................................................................................................1796 Failure Code [CA3717]...........................................................................................................................................1799 Failure Code [CA3718]...........................................................................................................................................1800 Failure Code [CA3725]...........................................................................................................................................1801 Failure Code [CA3748]...........................................................................................................................................1804 Failure Code [CA3751]...........................................................................................................................................1807 Failure Code [CA3755]...........................................................................................................................................1809 Failure Code [CA3866]...........................................................................................................................................1811 Failure Code [CA3867]...........................................................................................................................................1815 Failure Code [CA3868]...........................................................................................................................................1818 Failure Code [CA3899]...........................................................................................................................................1822 Failure Code [CA3911]...........................................................................................................................................1824 Failure Code [CA3912]...........................................................................................................................................1828 Failure Code [CA3932]...........................................................................................................................................1830 Failure Code [CA3933]...........................................................................................................................................1832 Failure Code [CA3934]...........................................................................................................................................1834 Failure Code [CA3935]...........................................................................................................................................1837 Failure Code [CA3936]...........................................................................................................................................1839 Failure Code [CA4151]...........................................................................................................................................1841 Failure Code [CA4152]...........................................................................................................................................1845 Failure Code [CA4155]...........................................................................................................................................1849 Failure Code [CA4156]...........................................................................................................................................1851 Failure Code [CA4157]...........................................................................................................................................1854 Failure Code [CA4158]...........................................................................................................................................1856 Failure Code [CA4159]...........................................................................................................................................1857 Failure Code [CA4161]...........................................................................................................................................1858 Failure Code [CA4162]...........................................................................................................................................1861 Failure Code [CA4163]...........................................................................................................................................1864 Failure Code [CA4164]...........................................................................................................................................1866 Failure Code [CA4165]...........................................................................................................................................1868 Failure Code [CA4166]...........................................................................................................................................1870 Failure Code [CA4168]...........................................................................................................................................1872 Failure Code [CA4169]...........................................................................................................................................1875 Failure Code [CA4171]...........................................................................................................................................1877 Failure Code [CA4249]...........................................................................................................................................1880 Failure Code [CA4251]...........................................................................................................................................1882 Failure Code [CA4259]...........................................................................................................................................1884 Failure Code [CA4261]...........................................................................................................................................1887 Failure Code [CA4277]...........................................................................................................................................1890 Failure Code [CA4281]...........................................................................................................................................1894 Failure Code [CA4459]...........................................................................................................................................1897 Failure Code [CA4461]...........................................................................................................................................1899 Failure Code [CA4658]...........................................................................................................................................1902 Failure Code [CA4731]...........................................................................................................................................1906 Failure Code [CA4732]...........................................................................................................................................1907 Failure Code [CA4739]...........................................................................................................................................1908 Failure Code [CA4768]...........................................................................................................................................1909 Failure Code [CA4769]...........................................................................................................................................1911 Failure Code [CA4842]...........................................................................................................................................1914 Failure Code [CA4952] (Machine with KOMTRAX Terminal)...........................................................................................................1918 Failure Code [CA4952] (Machine with Gateway Function Controller)................................................................................................1920 Failure Code [CA5115]...........................................................................................................................................1922 Failure Code [CA5179]...........................................................................................................................................1925 Failure Code [CA5181]...........................................................................................................................................1927 Failure Code [CA5383]...........................................................................................................................................1929 Failure Code [D150KA]...........................................................................................................................................1931 Failure Code [D150KB]...........................................................................................................................................1933 Failure Code [D150KY]...........................................................................................................................................1935 Failure Code [D160KA]...........................................................................................................................................1937 Failure Code [D160KB]...........................................................................................................................................1939 Failure Code [D160KY]...........................................................................................................................................1941 Failure Code [D191KA]...........................................................................................................................................1943 Failure Code [D191KB]...........................................................................................................................................1946 Failure Code [D191KY]...........................................................................................................................................1949 Failure Code [D192KA]...........................................................................................................................................1951 Failure Code [D192KB]...........................................................................................................................................1953 Failure Code [D192KY]...........................................................................................................................................1955 Failure Code [D193KA]...........................................................................................................................................1956 Failure Code [D193KB]...........................................................................................................................................1958 Failure Code [D193KY]...........................................................................................................................................1960 Failure Code [D193MC] (Applicable Machine: 100001 to 101011)....................................................................................................1962 Failure Code [D193MC] (Applicable Machine: 101012 and Up).......................................................................................................1964 Failure Code [D19JKZ]...........................................................................................................................................1966 Failure Code [D1E6KA]...........................................................................................................................................1968 Failure Code [D1E6KB]...........................................................................................................................................1970 Failure Code [D1E6KY]...........................................................................................................................................1972 Failure Code [D5ZHKA]...........................................................................................................................................1974 Failure Code [D5ZHKB]...........................................................................................................................................1976 Failure Code [D5ZHKZ]...........................................................................................................................................1978 Failure Code [D5ZHL6]...........................................................................................................................................1981 Failure Code [D811MC] (Machine with KOMTRAX Terminal)...........................................................................................................1983 Failure Code [D811MC] (Machine with Gateway Function Controller)................................................................................................1984 Failure Code [D862KA] (Machine with KOMTRAX Terminal)...........................................................................................................1985 Failure Code [D862KA] (Machine with Gateway Function Controller)................................................................................................1986 Failure Code [D8ALKA] (Machine with KOMTRAX Terminal)...........................................................................................................1987 Failure Code [D8ALKA] (Machine with Gateway Function Controller)................................................................................................1989 Failure Code [D8ALKB] (Machine with KOMTRAX Terminal)...........................................................................................................1991 Failure Code [D8ALKB] (Machine with Gateway Function Controller)................................................................................................1993 Failure Code [D8AQK4] (Machine with KOMTRAX Terminal)...........................................................................................................1995 Failure Code [D8AQK4] (Machine with Gateway Function Controller)................................................................................................1996 Failure Code [D8AQKR] (Machine with KOMTRAX Terminal)...........................................................................................................1997 Failure Code [D8AQKR] (Machine with Gateway Function Controller)................................................................................................1999 Failure Code [D8G1KT]...........................................................................................................................................2001 Failure Code [D8G6KT]...........................................................................................................................................2002 Failure Code [DAF0KT]...........................................................................................................................................2003 Failure Code [DAF0MB]...........................................................................................................................................2004 Failure Code [DAF0MC]...........................................................................................................................................2005 Failure Code [DAF3KK]...........................................................................................................................................2006 Failure Code [DAF8KB]...........................................................................................................................................2008 Failure Code [DAFDKB]...........................................................................................................................................2010 Failure Code [DAFGMC] (Machine with KOMTRAX Terminal)...........................................................................................................2012 Failure Code [DAFGMC] (Machine with Gateway Function Controller)................................................................................................2013 Failure Code [DAFLKA] (Machine with KOMTRAX Terminal)...........................................................................................................2014 Failure Code [DAFLKA] (Machine with Gateway Function Controller)................................................................................................2016 Failure Code [DAFLKB] (Machine with KOMTRAX Terminal)...........................................................................................................2018 Failure Code [DAFLKB] (Machine with Gateway Function Controller)................................................................................................2020 Failure Code [DAFQKR] (Machine with KOMTRAX Terminal)...........................................................................................................2022 Failure Code [DAFQKR] (Machine with Gateway Function Controller)................................................................................................2023 Failure Code [DAQ0KK]...........................................................................................................................................2024 Failure Code [DAQ0KT]...........................................................................................................................................2027 Failure Code [DAQ0MC]...........................................................................................................................................2028 Failure Code [DAQ1KA]...........................................................................................................................................2029 Failure Code [DAQ2KK]...........................................................................................................................................2031 Failure Code [DAQ2KT]...........................................................................................................................................2034 Failure Code [DAQ4KB]...........................................................................................................................................2037 Failure Code [DAQ9KQ]...........................................................................................................................................2039 Failure Code [DAQLKA] (Machine with KOMTRAX Terminal)...........................................................................................................2040 Failure Code [DAQLKA] (Machine with Gateway Function Controller)................................................................................................2042 Failure Code [DAQLKB] (Machine with KOMTRAX Terminal)...........................................................................................................2044 Failure Code [DAQLKB] (Machine with Gateway Function Controller)................................................................................................2046 Failure Code [DAQQKR]...........................................................................................................................................2048 Failure Code [DAQRKR]...........................................................................................................................................2049 Failure Code [DAQRMA]...........................................................................................................................................2050 Failure Code [DAZ9KQ]...........................................................................................................................................2051 Failure Code [DAZQKR]...........................................................................................................................................2052 Failure Code [DB2QKR] (Machine with KOMTRAX Terminal)...........................................................................................................2053 Failure Code [DB2QKR] (Machine with Gateway Function Controller)................................................................................................2058 Failure Code [DB2RKR]...........................................................................................................................................2063 Failure Code [DB90KK] (Machine with KOMTRAX Terminal)...........................................................................................................2069 Failure Code [DB90KK](Machine with Gateway Function Controller).................................................................................................2072 Failure Code [DB90KT]...........................................................................................................................................2075 Failure Code [DB90MC]...........................................................................................................................................2076 Failure Code [DB91KA]...........................................................................................................................................2077 Failure Code [DB92KK] (Machine with KOMTRAX Terminal)...........................................................................................................2079 Failure Code [DB92KK] (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011).........................................................2082 Failure Code [DB92KK] (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up)............................................................2085 Failure Code [DB92KT]...........................................................................................................................................2088 Failure Code [DB95KX] (Applicable Machine: 100001 to 101011)....................................................................................................2091 Failure Code [DB95KX] (Applicable Machine: 101012 and Up).......................................................................................................2095 Failure Code [DB96KX] (Applicable Machine: 100001 to 101011)....................................................................................................2099 Failure Code [DB96KX] (Applicable Machine: 101012 and Up).......................................................................................................2101 Failure Code [DB99KQ]...........................................................................................................................................2103 Failure Code [DB9LKA] (Machine with KOMTRAX Terminal)...........................................................................................................2104 Failure Code [DB9LKA] (Machine with Gateway Function Controller)................................................................................................2106 Failure Code [DB9LKB] (Machine with KOMTRAX Terminal)...........................................................................................................2108 Failure Code [DB9LKB] (Machine with Gateway Function Controller)................................................................................................2110 Failure Code [DB9QKR]...........................................................................................................................................2112 Failure Code [DB9RKR]...........................................................................................................................................2113 Failure Code [DB9RMA]...........................................................................................................................................2114 Failure Code [DBE5KX] (Applicable Machine: 100001 to 101011)....................................................................................................2115 Failure Code [DBE5KX] (Applicable Machine: 101012 and Up).......................................................................................................2117 Failure Code [DBE6KX]...........................................................................................................................................2119 Failure Code [DD1ALD]...........................................................................................................................................2121 Failure Code [DDAAL6]...........................................................................................................................................2123 Failure Code [DDB6L4]...........................................................................................................................................2125 Failure Code [DDD1LD]...........................................................................................................................................2128 Failure Code [DDK3KA]...........................................................................................................................................2130 Failure Code [DDK3KB]...........................................................................................................................................2133 Failure Code [DDK4KA]...........................................................................................................................................2136 Failure Code [DDK4KB]...........................................................................................................................................2139 Failure Code [DDK5L4]...........................................................................................................................................2141 Failure Code [DDK6KA]...........................................................................................................................................2143 Failure Code [DDK6KB]...........................................................................................................................................2146 Failure Code [DDKLKA] (Applicable Machine: 100001 to 101011)....................................................................................................2149 Failure Code [DDKLKA] (Applicable Machine: 101012 and Up).......................................................................................................2152 Failure Code [DDKLKB] (Applicable Machine: 100001 to 101011)....................................................................................................2155 Failure Code [DDKLKB] (Applicable Machine: 101012 and Up).......................................................................................................2157 Failure Code [DDNRKA]...........................................................................................................................................2159 Failure Code [DDNRKY] (Applicable Machine: 100001 to 101011)....................................................................................................2162 Failure Code [DDNRKY] (Applicable Machine: 101012 and Up).......................................................................................................2164 Failure Code [DDP5KA]...........................................................................................................................................2166 Failure Code [DDT0L4]...........................................................................................................................................2168 Failure Code [DDT4LD]...........................................................................................................................................2170 Failure Code [DDT9LD]...........................................................................................................................................2172 Failure Code [DDTALD]...........................................................................................................................................2174 Failure Code [DDW9LD]...........................................................................................................................................2176 Failure Code [DDWLLD]...........................................................................................................................................2178 Failure Code [DF10KA]...........................................................................................................................................2180 Failure Code [DF10KB]...........................................................................................................................................2183 Failure Code [DGF1KA]...........................................................................................................................................2186 Failure Code [DGF1KB]...........................................................................................................................................2188 Failure Code [DGH2KX]...........................................................................................................................................2190 Failure Code [DGR2KB]...........................................................................................................................................2192 Failure Code [DGR2KZ]...........................................................................................................................................2194 Failure Code [DGT1KA]...........................................................................................................................................2196 Failure Code [DGT1KB]...........................................................................................................................................2198 Failure Code [DH21KA]...........................................................................................................................................2200 Failure Code [DH21KB]...........................................................................................................................................2203 Failure Code [DHA4KA]...........................................................................................................................................2205 Failure Code [DHAAMA]...........................................................................................................................................2207 Failure Code [DHACMA]...........................................................................................................................................2209 Failure Code [DHPCKX]...........................................................................................................................................2211 Failure Code [DHPDKX]...........................................................................................................................................2214 Failure Code [DHT1KX]...........................................................................................................................................2217 Failure Code [DHT5KX]...........................................................................................................................................2220 Failure Code [DHT7KX]...........................................................................................................................................2223 Failure Code [DHT8KA]...........................................................................................................................................2226 Failure Code [DHT8KB]...........................................................................................................................................2229 Failure Code [DHT8ZG]...........................................................................................................................................2231 Failure Code [DHUDKA]...........................................................................................................................................2232 Failure Code [DHUDKB]...........................................................................................................................................2235 Failure Code [DJF1KA]...........................................................................................................................................2237 Failure Code [DK30KA]...........................................................................................................................................2239 Failure Code [DK30KY]...........................................................................................................................................2241 Failure Code [DK55KA]...........................................................................................................................................2243 Failure Code [DK55KY]...........................................................................................................................................2246 Failure Code [DK55L5]...........................................................................................................................................2248 Failure Code [DK59KA] (Applicable Machine: 100001 to 101011)....................................................................................................2249 Failure Code [DK59KA] (Applicable Machine: 101012 and Up).......................................................................................................2253 Failure Code [DK59KY] (Applicable Machine: 100001 to 101011)....................................................................................................2257 Failure Code [DK59KY] (Applicable Machine: 101012 and Up).......................................................................................................2261 Failure Code [DK59L8] (Applicable Machine: 100001 to 101011)....................................................................................................2265 Failure Code [DK59L8] (Applicable Machine: 101012 and Up).......................................................................................................2270 Failure Code [DK5AKA] (Applicable Machine: 100001 to 101011)....................................................................................................2275 Failure Code [DK5AKA] (Applicable Machine: 101012 and Up).......................................................................................................2279 Failure Code [DK5AKY] (Applicable Machine: 100001 to 101011)....................................................................................................2283 Failure Code [DK5AKY] (Applicable Machine: 101012 and Up).......................................................................................................2287 Failure Code [DK5BKA] (Applicable Machine: 100001 to 101011)....................................................................................................2291 Failure Code [DK5BKA] (Applicable Machine: 101012 and Up).......................................................................................................2295 Failure Code [DK5BKY] (Applicable Machine: 100001 to 101011)....................................................................................................2299 Failure Code [DK5BKY] (Applicable Machine: 101012 and Up).......................................................................................................2303 Failure Code [DK5BL8] (Applicable Machine: 100001 to 101011)....................................................................................................2307 Failure Code [DK5BL8] (Applicable Machine: 101012 and Up).......................................................................................................2312 Failure Code [DK5CKA] (Applicable Machine: 100001 to 101011)....................................................................................................2317 Failure Code [DK5CKA] (Applicable Machine: 101012 and Up).......................................................................................................2321 Failure Code [DK5CKY] (Applicable Machine: 100001 to 101011)....................................................................................................2325 Failure Code [DK5CKY] (Applicable Machine: 101012 and Up).......................................................................................................2329 Failure Code [DK5DKA] (Applicable Machine: 100001 to 101011)....................................................................................................2333 Failure Code [DK5DKA] (Applicable Machine: 101012 and Up).......................................................................................................2336 Failure Code [DK5DKY] (Applicable Machine: 100001 to 101011)....................................................................................................2339 Failure Code [DK5DKY] (Applicable Machine: 101012 and Up).......................................................................................................2342 Failure Code [DK5DL8] (Applicable Machine: 100001 to 101011)....................................................................................................2345 Failure Code [DK5DL8] (Applicable Machine: 101012 and Up).......................................................................................................2350 Failure Code [DK5EKA] (Applicable Machine: 100001 to 101011)....................................................................................................2355 Failure Code [DK5EKA] (Applicable Machine: 101012 and Up).......................................................................................................2358 Failure Code [DK5EKY] (Applicable Machine: 100001 to 101011)....................................................................................................2361 Failure Code [DK5EKY] (Applicable Machine: 101012 and Up).......................................................................................................2364 Failure Code [DK5FKA]...........................................................................................................................................2367 Failure Code [DK5FKY]...........................................................................................................................................2370 Failure Code [DK5FL8]...........................................................................................................................................2373 Failure Code [DK5GKA]...........................................................................................................................................2377 Failure Code [DK5GKY]...........................................................................................................................................2380 Failure Code [DKA0KA]...........................................................................................................................................2383 Failure Code [DKA0KY]...........................................................................................................................................2386 Failure Code [DKA0L0]...........................................................................................................................................2389 Failure Code [DKA1KA]...........................................................................................................................................2392 Failure Code [DKA1KY]...........................................................................................................................................2395 Failure Code [DKD0KA]...........................................................................................................................................2398 Failure Code [DKD0KY]...........................................................................................................................................2400 Failure Code [DKD0L8]...........................................................................................................................................2402 Failure Code [DLF1KA]...........................................................................................................................................2403 Failure Code [DLF1LC]...........................................................................................................................................2405 Failure Code [DLM3KA]...........................................................................................................................................2407 Failure Code [DLM3LC]...........................................................................................................................................2409 Failure Code [DLT3KA]...........................................................................................................................................2411 Failure Code [DLT3LC]...........................................................................................................................................2413 Failure Code [DPQ1KR]...........................................................................................................................................2415 Failure Code [DPQ2KR]...........................................................................................................................................2418 Failure Code [DPQ3KR]...........................................................................................................................................2421 Failure Code [DSJ0KR]...........................................................................................................................................2424 Failure Code [DT20KB] (Applicable Machine: 100001 to 101011)....................................................................................................2427 Failure Code [DT20KB] (Applicable Machine: 101012 and Up).......................................................................................................2429 Failure Code [DT22KB]...........................................................................................................................................2431 Failure Code [DT23KB]...........................................................................................................................................2433 Failure Code [DV00KB]...........................................................................................................................................2435 Failure Code [DW4PKA]...........................................................................................................................................2437 Failure Code [DW4PKB]...........................................................................................................................................2439 Failure Code [DW4PKY]...........................................................................................................................................2441 Failure Code [DW4QKA]...........................................................................................................................................2443 Failure Code [DW4QKB]...........................................................................................................................................2445 Failure Code [DW4QKY]...........................................................................................................................................2447 Failure Code [DW4RKA]...........................................................................................................................................2449 Failure Code [DW4RKB]...........................................................................................................................................2451 Failure Code [DW4RKY]...........................................................................................................................................2453 Failure Code [DW4SKA]...........................................................................................................................................2455 Failure Code [DW4SKB]...........................................................................................................................................2457 Failure Code [DW4SKY]...........................................................................................................................................2459 Failure Code [DW7BKA]...........................................................................................................................................2461 Failure Code [DW7BKB]...........................................................................................................................................2463 Failure Code [DW7BKY]...........................................................................................................................................2465 Failure Code [DWM1KA] (Applicable Machine: 100001 to 101011)....................................................................................................2467 Failure Code [DWM1KA] (Applicable Machine: 101012 and Up).......................................................................................................2469 Failure Code [DWM1KB] (Applicable Machine: 100001 to 101011)....................................................................................................2471 Failure Code [DWM1KB] (Applicable Machine: 101012 and Up).......................................................................................................2473 Failure Code [DWM1KY]...........................................................................................................................................2475 Failure Code [DWN6KA]...........................................................................................................................................2477 Failure Code [DWN6KB]...........................................................................................................................................2479 Failure Code [DWN6KY]...........................................................................................................................................2481 Failure Code [DWN8KA]...........................................................................................................................................2483 Failure Code [DWN8KB]...........................................................................................................................................2485 Failure Code [DWN8KY]...........................................................................................................................................2487 Failure Code [DX16KA]...........................................................................................................................................2489 Failure Code [DX16KB]...........................................................................................................................................2491 Failure Code [DX16KY]...........................................................................................................................................2493 Failure Code [DXA1KA]...........................................................................................................................................2495 Failure Code [DXA1KB]...........................................................................................................................................2497 Failure Code [DXA1KY]...........................................................................................................................................2499 Failure Code [DXANKA]...........................................................................................................................................2501 Failure Code [DXANKB]...........................................................................................................................................2503 Failure Code [DXANKY]...........................................................................................................................................2505 Failure Code [DXF0KA]...........................................................................................................................................2507 Failure Code [DXF0KB]...........................................................................................................................................2509 Failure Code [DXF0KY]...........................................................................................................................................2511 Failure Code [DXH1KA]...........................................................................................................................................2513 Failure Code [DXH1KB]...........................................................................................................................................2515 Failure Code [DXH1KY]...........................................................................................................................................2517 Failure Code [DXH4KA]...........................................................................................................................................2519 Failure Code [DXH4KB]...........................................................................................................................................2521 Failure Code [DXH4KY]...........................................................................................................................................2523 Failure Code [DXH5KA]...........................................................................................................................................2525 Failure Code [DXH5KB]...........................................................................................................................................2527 Failure Code [DXH5KY]...........................................................................................................................................2529 Failure Code [DXH6KA]...........................................................................................................................................2531 Failure Code [DXH6KB]...........................................................................................................................................2533 Failure Code [DXH6KY]...........................................................................................................................................2535 Failure Code [DXH7KA]...........................................................................................................................................2537 Failure Code [DXH7KB]...........................................................................................................................................2539 Failure Code [DXH7KY]...........................................................................................................................................2541 Failure Code [DXH8KA]...........................................................................................................................................2543 Failure Code [DXH8KB]...........................................................................................................................................2545 Failure Code [DXH8KY]...........................................................................................................................................2547 Failure Code [DXHHKA]...........................................................................................................................................2549 Failure Code [DXHHKB]...........................................................................................................................................2551 Failure Code [DXHHKY]...........................................................................................................................................2553 Failure Code [DXHJKA]...........................................................................................................................................2555 Failure Code [DXHJKB]...........................................................................................................................................2557 Failure Code [DXHJKY]...........................................................................................................................................2559 Failure Code [DXHKKA]...........................................................................................................................................2561 Failure Code [DXHKKB]...........................................................................................................................................2563 Failure Code [DXHKKY]...........................................................................................................................................2565 Failure Code [DXHLKA]...........................................................................................................................................2567 Failure Code [DXHLKB]...........................................................................................................................................2569 Failure Code [DXHLKY]...........................................................................................................................................2571 Failure Code [DXHMKA]...........................................................................................................................................2573 Failure Code [DXHMKB]...........................................................................................................................................2575 Failure Code [DXHMKY]...........................................................................................................................................2577 Failure Code [DY30MA]...........................................................................................................................................2579 Failure Code [DY30MC]...........................................................................................................................................2583 Failure Code [DY30ME]...........................................................................................................................................2588 Failure Code [F313KA]...........................................................................................................................................2590 Failure Code [F313KB]...........................................................................................................................................2592 Failure Code [F314KA]...........................................................................................................................................2593 Failure Code [F314KB]...........................................................................................................................................2595 Failure Code [F315KB]...........................................................................................................................................2597 Failure Code [F315KY]...........................................................................................................................................2599 Failure Code [F316KB]...........................................................................................................................................2601 Failure Code [F316KY]...........................................................................................................................................2603 Failure Code [F318KB]...........................................................................................................................................2605 Failure Code [F318KY]...........................................................................................................................................2607 Failure Code [F31AKB]...........................................................................................................................................2608 Failure Code [F31AKY]...........................................................................................................................................2610 Failure Code [F31BKB]...........................................................................................................................................2612 Failure Code [F31BKY]...........................................................................................................................................2614 Failure Code [F31CKB]...........................................................................................................................................2616 Failure Code [F31CKY]...........................................................................................................................................2618 Failure Code [F31DKB]...........................................................................................................................................2620 Failure Code [F31DKY]...........................................................................................................................................2622 Failure Code [F31EKB]...........................................................................................................................................2624 Failure Code [F31EKY]...........................................................................................................................................2626 Failure Code [FS10ZE]...........................................................................................................................................2628 Failure Code [LA00L3]...........................................................................................................................................2629 Troubleshooting of Electrical System (E-Mode).......................................................................................................................2630 Engine Does Not Start (Engine Does Not Crank)...................................................................................................................2630 Manual Preheating System Does Not Operate.......................................................................................................................2639 Automatic Preheating System Does Not Operate....................................................................................................................2642 While Preheating is in Operation, Preheating Monitor Does Not Come On...........................................................................................2645 The LCD Unit, LED Unit, and Meter Unit of the Machine Monitor Show Nothing......................................................................................2647 LCD Unit on Machine Monitor Shows Nothing.......................................................................................................................2650 Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers)...........................................................................2653 LCD Screen on Machine Monitor Does Not Show Correctly...........................................................................................................2656 Meter Unit Display on Machine Monitor is Abnormal...............................................................................................................2659 Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal....................................................................................................2662 LED Unit Lamp on Machine Monitor is Abnormal....................................................................................................................2665 Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly.............................................................2667 Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate......................................................................................2670 Switch Panel Buzzer of Machine Monitor is Abnormal..............................................................................................................2673 Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally................................................................................2676 DEF Level is Not Shown Correctly................................................................................................................................2677 Rearview Monitor Does Not Come On or Backlight Flickers.........................................................................................................2680 Rearview Monitor Images are Not Shown Clearly...................................................................................................................2683 Rearview Monitor Brightness Cannot be Adjusted..................................................................................................................2686 Night Mode Lamp of Rearview Monitor is Abnormal.................................................................................................................2690 Air Cleaner Clogging Indicator Lamp Does Not Come On............................................................................................................2692 Radiator Coolant Level Caution Lamp Does Not Come On............................................................................................................2694 Parking Brake Indicator Lamp Does Not Light When Parking Brake is Set to ON (Parking) Position..................................................................2696 Brake Oil Pressure Caution Lamp Does Not Come On When Front Brake Accumulator Oil Pressure is Low...............................................................2700 Brake Oil Pressure Caution Lamp Does Not Come On When Rear Brake Accumulator Oil Pressure is Low................................................................2701 Fuel Gauge Does Not Show Normally...............................................................................................................................2702 Torque Converter Oil Temperature Gauge Does Not Increase, or Torque Converter Oil Temperature Caution Lamp Does Not Come On.....................................2704 Hydraulic Oil Temperature Gauge Does Not Rise or Hydraulic Oil Temperature Caution Lamp Does Not Come On........................................................2705 Seatbelt Caution Lamp Does Not Show Normally....................................................................................................................2707 Alarm Buzzer Does Not Operate...................................................................................................................................2708 Alarm Buzzer Does Not Stop......................................................................................................................................2710 Kickdown Does Not Operate When Kickdown Switch is ON Position...................................................................................................2711 Hold Does Not Operate When Hold Switch is on Position...........................................................................................................2713 Parking Brake Does Not Operate Even If It is Applied, or the Brake Drags in Forward or Reverse Travel When Parking Brake is Released............................2715 Transmission Cut-off Mode is Not Selected or Not Released.......................................................................................................2719 Transmission Cut-off Setting Cannot be Released.................................................................................................................2721 Directional Selector (FNR) Switch Mode is Not Selected or Not Released..........................................................................................2723 Engine Mode Selector Function Does Not Operate Normally When Engine Power Mode Selector Switch is Operated......................................................2725 Flow of Loader Pump Does Not Increase from the Minimum Rate.....................................................................................................2727 ECSS Function Cannot be Selected or Cannot be Released..........................................................................................................2728 ECSS Function Cannot be Selected or Cannot be Released (For AJSS Spec)..........................................................................................2730 Horn Does Not Sound.............................................................................................................................................2732 Horn Does Not Sound (For AJSS Spec).............................................................................................................................2735 Horn Does Not Stop..............................................................................................................................................2738 Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On..........................................................................................................2741 Headlamp, Clearance Lamp, and Tail Lamp Do Not Light (For AJSS Spec)............................................................................................2743 Clearance Lamp and Tail Lamp Do Not Come On or Go Out...........................................................................................................2745 Clearance Lamp and Tail Lamp Do Not Come On or Go Out (For AJSS Spec)...........................................................................................2749 Clearance Lamp and Tail Lamp Do Not Come on or Go Out (For European Union)......................................................................................2753 High and Low Beams of Headlamp Do Not Come On or Go Out.........................................................................................................2757 High and Low Beams of Headlamp Do Not Come On or Go Out (For AJSS Spec).........................................................................................2761 High and Low Beams of Headlamp Do Not Come On or Go Out (EU Specification)......................................................................................2765 Low Beam of Headlamp Does Not Come On or Go Out.................................................................................................................2769 Low Beam of Headlamp Does Not Come On or Go Out (For AJSS Spec).................................................................................................2771 Low Beam of Headlamp Does Not Come On or Go Out (For European Union)............................................................................................2773 High Beam of Headlamp Does Not Come On or Go Out................................................................................................................2775 High Beam of Headlamp Does Not Come On or Go Out (For AJSS Spec)................................................................................................2777 High Beam of Headlamp Does Not Come On or Go Out (For European Union)...........................................................................................2779 Front Working Lamp Does Not Come On or Go Out...................................................................................................................2781 Front Working Lamp Does Not Come On or Go Out (EU Specifications)...............................................................................................2786 Front Working Lamp, Additional Front Working Lamp, and Additional Side Working Lamp Do Not Come on or Go off (Machine with Additional LED Working Lamp).........2791 Rear Working Lamp Does Not Come On or Go Out....................................................................................................................2797 Rear Working Lamp Does Not Come On or Go Out (For European Union)...............................................................................................2801 Additional Rear Working Lamp Does Not Come on or Go off (Machine with Additional LED Working Lamp)..............................................................2806 Turn Signal Lamp and Hazard Lamp Do Not Come On or Go Out.......................................................................................................2811 All of Turn Signal Lamps and Hazard Lamps Do Not Come On or Go Out (For AJSS Spec)..............................................................................2814 Turn Signal Lamp Does Not Come On or Go Out.....................................................................................................................2817 Turn Signal Lamps Do Not Come On or Go Out (For AJSS Spec)......................................................................................................2820 Turn Signal Lamps Do Not Come On or Go Out (For European Union).................................................................................................2824 Hazard Lamp Does Not Come On or Go Out..........................................................................................................................2827 Hazard Lamp Does Not Come On or Go Out (For European Union).....................................................................................................2832 Brake Lamp Does Not Come On or Stays Lit........................................................................................................................2836 Backup Lamp Does Not Come On or Stays Lit.......................................................................................................................2840 Backup Buzzer Does Not Sound or Continues to Sound..............................................................................................................2843 Front Wiper Does Not Operate....................................................................................................................................2845 Front Wiper Does Not Operate (For AJSS Spec)....................................................................................................................2849 Rear Wiper Does Not Operate.....................................................................................................................................2853 Rear Wiper Does Not Operate (For AJSS Spec).....................................................................................................................2856 Fuel Feed Pump Does Not Operate or Stop Automatically...........................................................................................................2859 Fan Does Not Rotate in Reverse..................................................................................................................................2862 Fan Remains Rotated in Reverse..................................................................................................................................2863 Window Washer Does Not Operate..................................................................................................................................2864 Window Washer Does Not Operate (For AJSS Spec)..................................................................................................................2867 KOMTRAX System Does Not Operate Correctly.......................................................................................................................2870 Auto-Greasing Pump Display Shows [FCS]..........................................................................................................................2871 Auto-Greasing Pump Display Shows [FLL]..........................................................................................................................2873 Auto-Greasing System Does Not Operate or Stop...................................................................................................................2874 When Work Equipment Lock Switch is Operated, Work Equipment is Not Locked or Unlocked...........................................................................2876 Troubleshooting for Hydraulic and Mechanical Systems (H Mode).......................................................................................................2878 Information Shown in Troubleshooting Table (H-Mode).............................................................................................................2878 Failure Mode and Cause Table....................................................................................................................................2879 Machine Does Not Start..........................................................................................................................................2899 Lockup is Not Released..........................................................................................................................................2903 Torque Converter Lockup Clutch Does Not Engage..................................................................................................................2904 Travel Speed is Slow, Bucket Thrust Force is Weak, Gradability is Low, or Gear Speed Does Not Shift.............................................................2905 Strong Shocks are Made When You Start Machine or Shift Gears....................................................................................................2909 Time Lag is Large When You Start Machine or Shift Gears.........................................................................................................2912 Torque Converter Oil Temperature is High........................................................................................................................2915 Machine Does Not Turn (For Steering Wheel Spec).................................................................................................................2918 Machine Does Not Turn (AJSS Specification)......................................................................................................................2920 Turning Response is Unsatisfactory (For Steering Wheel Specification)...........................................................................................2922 Turning Response is Unsatisfactory (AJSS Specification).........................................................................................................2924 Steering Wheel is Heavy to Operate..............................................................................................................................2926 Machine Sways or Large Shocks are Made While Machine Turns (For Steering Wheel Specification)...................................................................2927 Machine Sways or Large Shocks are Made While Machine Turns (AJSS Specification).................................................................................2929 Turning Radius is Different on the Left and Right...............................................................................................................2931 Wheel Brakes Do Not Operate or are Weak.........................................................................................................................2932 Wheel Brakes are Not Released or Drag...........................................................................................................................2934 Parking Brake Does Not Operate or is Weak.......................................................................................................................2935 Parking Brake is Not Released or Drags..........................................................................................................................2936 Boom Does Not Rise..............................................................................................................................................2938 Boom Moves Slow or Lacks Lifting Force..........................................................................................................................2940 Rising Boom Slows Down at Specified Height......................................................................................................................2942 Lift Cylinders Can Not Hold Bucket on Ground....................................................................................................................2943 Hydraulic Drift of Boom is Large................................................................................................................................2945 Boom Moves Up and Down During Operation.........................................................................................................................2946 Bucket Does Not Tilt Back.......................................................................................................................................2947 Bucket Moves Slow or Lacks Tilt-Back Force......................................................................................................................2949 Bucket Slows Down During Tilt Back Operation....................................................................................................................2951 Bucket Cylinder Does Not Hold Bucket on Ground..................................................................................................................2952 Hydraulic Drift of Bucket is Large..............................................................................................................................2954 Bucket Tilts Back and Forth When You Carry Load (Work Equipment Valve is in Hold)...............................................................................2955 Boom and Bucket Control Levers Do Not Move Smoothly and are Heavy to Move.......................................................................................2956 Engine Speed Drops Largely or Engine Stops When You Operate Work Equipment......................................................................................2957 Large Shocks are Made When Work Equipment Starts to Move and Stops..............................................................................................2958 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves................................................................................2961 ECSS Does Not Operate and Machine Pitches and Bounces...........................................................................................................2962 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate).....................................................................................................2963 Unusual Noise is Heard from Around Fan..........................................................................................................................2965 Troubleshooting of Engine (S-Mode)..................................................................................................................................2966 Information Shown in Troubleshooting Table (S-Mode).............................................................................................................2966 Engine Does Not Crank When Starting Switch is Turned to Start Position..........................................................................................2967 Engine Cranks but No Exhaust Smoke Comes Out....................................................................................................................2968 Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start).........................................................................2969 Engine Startability is Unsatisfactory...........................................................................................................................2970 Engine Does Not Pick Up Smoothly................................................................................................................................2972 Engine Stops During Operation...................................................................................................................................2974 Engine Does Not Rotate Smoothly.................................................................................................................................2976 Engine Lacks Output (or Lacks Power)............................................................................................................................2977 KDPF Becomes Clogged in a Short Time............................................................................................................................2979 Engine Oil Consumption is Excessive.............................................................................................................................2981 Engine Oil Becomes Dirty Quickly................................................................................................................................2982 Fuel Consumption is Excessive...................................................................................................................................2983 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)...........................................................................................2984 Engine Oil Pressure Drops.......................................................................................................................................2985 Fuel Mixes Into Engine Oil......................................................................................................................................2987 Water Mixes Into Engine Oil (Milky).............................................................................................................................2988 Coolant Temperature Increases Too High (Overheat)...............................................................................................................2989 Unusual Noise is Heard..........................................................................................................................................2990 Vibration is Excessive..........................................................................................................................................2991 Air Cannot be Bled from Fuel Circuit............................................................................................................................2992 Active Regeneration is Done Frequently..........................................................................................................................2993 Active Regeneration Continues Long..............................................................................................................................2995 White Smoke is Exhausted During Active Regeneration.............................................................................................................2996 DEF Consumption is Excessive....................................................................................................................................2997 There is an Unusual Smell (Irritating Odor).....................................................................................................................2999 Foreign Materials Enter DEF (DEF Increases).....................................................................................................................3000 Troubleshooting for Auto-Greasing System............................................................................................................................3001 Outline of Failure Display......................................................................................................................................3001 Troubleshooting for FCS.........................................................................................................................................3002 Troubleshooting for Auto-Greasing Pump..........................................................................................................................3003 Replacement of Pump Element.....................................................................................................................................3006 Troubleshooting for Grease Supply System........................................................................................................................3007 Replace Auto-Greasing Controller................................................................................................................................3009 Assembly procedure when disassembled in troubleshooting.........................................................................................................3010 50 Disassembly and Assembly.............................................................................................................................................3011 Table of Contents...................................................................................................................................................3012 Precautions Before Work.............................................................................................................................................3017 Abbreviation List...................................................................................................................................................3018 Related Information on Disassembly and Assembly.....................................................................................................................3024 How to Read This Manual.........................................................................................................................................3024 Coating Materials List..........................................................................................................................................3025 Special Tool List...............................................................................................................................................3030 Sketches of Special Tools.......................................................................................................................................3052 Engine and Cooling System...........................................................................................................................................3063 Remove and Install Supply Pump Assembly.........................................................................................................................3063 How to Remove Supply Pump Assembly..........................................................................................................................3063 How to Install Supply Pump Assembly.........................................................................................................................3067 Remove and Install Injector Assembly............................................................................................................................3073 How to Remove Injector Assembly.............................................................................................................................3073 How to Install Injector Assembly............................................................................................................................3078 Remove and Install Fuel Doser Assembly..........................................................................................................................3084 How to Remove Fuel Doser Assembly...........................................................................................................................3084 How to Install Fuel Doser Assembly..........................................................................................................................3085 Remove and Install Cylinder Head Assembly.......................................................................................................................3088 How to Remove Cylinder Head Assembly........................................................................................................................3088 How to Install Cylinder Head Assembly.......................................................................................................................3100 Remove and Install EGR Valve Assembly...........................................................................................................................3117 How to Remove EGR Valve Assembly............................................................................................................................3117 How to Install EGR Valve Assembly...........................................................................................................................3117 Remove and Install EGR Cooler Assembly..........................................................................................................................3119 How to Remove EGR Cooler Assembly...........................................................................................................................3119 How to Install EGR Cooler Assembly..........................................................................................................................3121 Remove and Install Starter Assembly.............................................................................................................................3124 How to Remove Starting Motor Assembly.......................................................................................................................3124 How to Install Starting Motor Assembly......................................................................................................................3125 Remove and Install Air Conditioner Compressor Belt..............................................................................................................3127 How to Remove Air Conditioner Compressor Belt...............................................................................................................3127 How to Install Air Conditioner Compressor Belt..............................................................................................................3129 Remove and Install Alternator Belt..............................................................................................................................3132 How to Remove Alternator Belt...............................................................................................................................3132 How to Install Alternator Belt..............................................................................................................................3134 Remove and Install Automatic Tensioner..........................................................................................................................3136 How to Remove Automatic Tensioner...........................................................................................................................3136 How to Install Automatic Tensioner..........................................................................................................................3136 Remove and Install Radiator Assembly............................................................................................................................3137 How to Remove Radiator Assembly.............................................................................................................................3137 How to Install Radiator Assembly............................................................................................................................3142 Remove and Install Cooling Fan and Fan Motor Assembly...........................................................................................................3147 How to Remove Cooling Fan and Fan Motor Assembly............................................................................................................3147 How to Install Cooling Fan and Fan Motor Assembly...........................................................................................................3151 Remove and Install Hydraulic Oil Cooler Assembly................................................................................................................3154 How to Remove Hydraulic Oil Cooler Assembly.................................................................................................................3154 How to Install Hydraulic Oil Cooler Assembly................................................................................................................3156 Remove and Install Aftercooler Assembly.........................................................................................................................3158 How to Remove Aftercooler Assembly..........................................................................................................................3158 How to Install Aftercooler Assembly.........................................................................................................................3161 Remove and Install Power Train Oil Cooler Assembly..............................................................................................................3166 How to Remove Power Train Oil Cooler Assembly...............................................................................................................3166 How to Install Power Train Oil Cooler Assembly..............................................................................................................3171 Remove and Install Engine, Torque Converter, and Transmission Assembly..........................................................................................3177 How to Remove Engine, Torque Converter, and Transmission Assembly...........................................................................................3178 How to Install Engine, Torque Converter, and Transmission Assembly..........................................................................................3195 Disconnect and Connect Engine, Torque Converter, and Transmission Assembly......................................................................................3212 How to Disconnect Engine, Torque Converter, and Transmission Assembly.......................................................................................3212 How to Connect Engine, Torque Converter, and Transmission Assembly..........................................................................................3213 Remove and Install Engine Front Oil Seal........................................................................................................................3214 How to Remove Engine Front Oil Seal.........................................................................................................................3214 How to Install Engine Front Oil Seal........................................................................................................................3216 Remove and Install Engine Rear Oil Seal.........................................................................................................................3219 How to Remove Engine Rear Oil Seal..........................................................................................................................3219 How to Install Engine Rear Oil Seal.........................................................................................................................3220 Remove and Install Engine Hood Assembly.........................................................................................................................3226 How to Remove Engine Hood Assembly..........................................................................................................................3226 How to Install Engine Hood Assembly.........................................................................................................................3233 Remove and Install Fuel Tank Assembly...........................................................................................................................3239 How to Remove Fuel Tank Assembly............................................................................................................................3239 How to Install Fuel Tank Assembly...........................................................................................................................3244 Remove and Install DEF Tank Assembly............................................................................................................................3248 How to Remove DEF Tank Assembly.............................................................................................................................3248 How to Install DEF Tank Assembly............................................................................................................................3252 Remove and Install DEF Tank Sensor Flange Assembly..............................................................................................................3256 How to Remove DEF Tank Sensor Flange Assembly...............................................................................................................3256 How to Install DEF Tank Sensor Flange Assembly..............................................................................................................3261 Remove and Install DEF Tank Sensor..............................................................................................................................3265 How to Remove DEF Tank Sensor...............................................................................................................................3265 How to Install DEF Tank Sensor..............................................................................................................................3266 Remove and Install DEF Tank Strainer............................................................................................................................3273 How to Remove DEF Tank Strainer.............................................................................................................................3273 How to Install DEF Tank Strainer............................................................................................................................3273 Remove and Install KDPF Assembly................................................................................................................................3275 How to Remove KDPF Assembly.................................................................................................................................3276 How to Install KDPF Assembly................................................................................................................................3289 Disassemble and Assemble KDPF Assembly..........................................................................................................................3304 How to Disassemble KDPF Assembly............................................................................................................................3304 How to Assemble KDPF Assembly...............................................................................................................................3308 Remove and Install SCR Assembly.................................................................................................................................3314 How to Remove SCR Assembly..................................................................................................................................3315 How to Install SCR Assembly.................................................................................................................................3325 Remove and Install KDPF and SCR Assembly........................................................................................................................3339 How to Remove KDPF and SCR Assembly.........................................................................................................................3340 How to Install KDPF and SCR Assembly........................................................................................................................3351 Remove and Install Bellows Pipe Assembly........................................................................................................................3362 How to Remove Bellows Pipe Assembly.........................................................................................................................3362 How to Install Bellows Pipe Assembly........................................................................................................................3367 Remove and Install KCCV Assembly................................................................................................................................3375 How to Remove KCCV Assembly.................................................................................................................................3375 How to Install KCCV Assembly................................................................................................................................3375 Remove and Install VGT Assembly.................................................................................................................................3377 How to Remove VGT Assembly..................................................................................................................................3377 How to Install VGT Assembly.................................................................................................................................3383 Remove and Install DEF Mixing Tube..............................................................................................................................3389 How to Remove DEF Mixing Tube...............................................................................................................................3389 How to Install DEF Mixing Tube..............................................................................................................................3397 Remove and Install DEF Injector.................................................................................................................................3406 How to Remove DEF Injector..................................................................................................................................3406 How to Install DEF Injector.................................................................................................................................3410 Remove and Install DEF Pump.....................................................................................................................................3414 How to Remove DEF Pump......................................................................................................................................3414 How to Install DEF Pump.....................................................................................................................................3417 Remove and Install DEF Hose.....................................................................................................................................3420 How to Remove DEF Hose......................................................................................................................................3420 How to Install DEF Hose.....................................................................................................................................3430 Remove and Install Air Cleaner Assembly.........................................................................................................................3441 How to Remove Air Cleaner Assembly..........................................................................................................................3441 How to Install Air Cleaner Assembly.........................................................................................................................3442 Remove and Install Air Conditioner Compressor Assembly..........................................................................................................3444 How to Remove Air Conditioner Compressor Assembly...........................................................................................................3444 How to Install Air Conditioner Compressor Assembly..........................................................................................................3445 Remove and Install Air Conditioner Condenser Assembly...........................................................................................................3447 How to Remove Air Conditioner Condenser Assembly............................................................................................................3447 How to Install Air Conditioner Condenser Assembly...........................................................................................................3448 Power Train.........................................................................................................................................................3450 Disassemble and Assemble Torque Converter Assembly..............................................................................................................3450 How to Disassemble Torque Converter Assembly................................................................................................................3450 How to Assemble Torque Converter Assembly...................................................................................................................3455 Disassemble and Assemble Transmission Assembly..................................................................................................................3462 How to Disassemble Transmission Assembly....................................................................................................................3464 How to Assemble Transmission Assembly.......................................................................................................................3482 Disassemble and Assemble Transmission Clutch Pack Assembly......................................................................................................3509 How to Disassemble Transmission Clutch Pack Assembly........................................................................................................3510 How to Assemble Transmission Clutch Pack Assembly...........................................................................................................3526 Remove and Install Front Axle Assembly..........................................................................................................................3546 How to Remove Front Axle Assembly...........................................................................................................................3546 How to Install Front Axle Assembly..........................................................................................................................3548 Remove and Install Rear Axle Assembly...........................................................................................................................3550 How to Remove Rear Axle Assembly............................................................................................................................3550 How to Install Rear Axle Assembly...........................................................................................................................3557 Disassemble and Assemble Axle Housing Assembly..................................................................................................................3565 How to Disassemble Axle Housing Assembly....................................................................................................................3566 How to Assemble Axle Housing Assembly.......................................................................................................................3571 Disassemble and Assemble Axle Housing Assembly (Specifications of 5.5m3 Bucket).................................................................................3579 How to Disassemble Axle Housing Assembly (Specifications of 5.5m3 Bucket)...................................................................................3580 How to Assemble Axle Housing Assembly (Specifications of 5.5m3 Bucket)......................................................................................3585 Disassemble and Assemble Differential Assembly..................................................................................................................3593 How to Disassemble Differential Assembly....................................................................................................................3594 How to Assemble Differential Assembly.......................................................................................................................3603 Disassemble and Assemble Differential Assembly (Specifications of 5.5m3 Bucket).................................................................................3622 How to Disassemble Differential Assembly (Specifications of 5.5m3 Bucket)...................................................................................3623 How to Assemble Differential Assembly (Specifications of 5.5m3 Bucket)......................................................................................3633 Steering System.....................................................................................................................................................3651 Remove and Install Steering Valve Assembly......................................................................................................................3651 How to Remove Steering Valve Assembly.......................................................................................................................3651 How to Install Steering Valve Assembly......................................................................................................................3654 Remove and Install Rotary Valve Assembly (For AJSS Spec)........................................................................................................3657 How to Remove Rotary Valve Assembly.........................................................................................................................3657 How to Install Rotary Valve Assembly........................................................................................................................3662 Brake System........................................................................................................................................................3671 Remove and Install Parking Brake Disc and Plate.................................................................................................................3671 How to Remove Parking Brake Disc and Plate..................................................................................................................3671 How to Install Parking Brake Disc and Plate.................................................................................................................3675 Undercarriage and Frame.............................................................................................................................................3679 Remove and Install Center Hinge Pin.............................................................................................................................3679 How to Remove Center Hinge Pin..............................................................................................................................3679 How to Install Center Hinge Pin.............................................................................................................................3685 Remove and Install Counterweight Assembly.......................................................................................................................3692 How to Remove Counterweight Assembly........................................................................................................................3692 How to Install Counterweight Assembly.......................................................................................................................3694 Remove and Install Full-Length Fender Assembly..................................................................................................................3697 How to Remove Full-Length Fender Assembly...................................................................................................................3697 How to Install Full-Length Fender Assembly..................................................................................................................3698 Hydraulic System....................................................................................................................................................3699 Remove and Install Hydraulic Tank Assembly......................................................................................................................3699 How to Remove Hydraulic Tank Assembly.......................................................................................................................3699 How to Install Hydraulic Tank Assembly......................................................................................................................3704 Remove and Install Work Equipment Pump and Cooling Fan Pump Assembly............................................................................................3710 How to Remove Work Equipment Pump and Cooling Fan Pump Assembly.............................................................................................3710 How to Install Work Equipment Pump and Cooling Fan Pump Assembly............................................................................................3713 Remove and Install Steering Pump and Power Train Pump Assembly..................................................................................................3715 How to Remove Steering Pump and Power Train Pump Assembly...................................................................................................3715 How to Install Steering Pump and Power Train Pump Assembly..................................................................................................3718 Remove and Install Control Valve Assembly.......................................................................................................................3721 How to Remove Control Valve Assembly........................................................................................................................3721 How to Install Control Valve Assembly.......................................................................................................................3725 Work Equipment......................................................................................................................................................3729 Remove and Install Work Equipment Assembly......................................................................................................................3729 How to Remove Work Equipment Assembly.......................................................................................................................3729 How to Install Work Equipment Assembly......................................................................................................................3734 Disassemble and Assemble Hydraulic Cylinder Assembly............................................................................................................3740 How to Disassemble Hydraulic Cylinder Assembly..............................................................................................................3741 How to Assemble Hydraulic Cylinder Assembly.................................................................................................................3744 CAB Related Parts...................................................................................................................................................3750 Remove and Install Operator Cab Assembly........................................................................................................................3750 How to Remove Operator Cab Assembly.........................................................................................................................3750 How to Install Operator Cab Assembly........................................................................................................................3757 Remove and Install Operator Cab Glass (Adhered Glass)...........................................................................................................3764 How to Remove Operator Cab Glass (Adhered Glass)............................................................................................................3764 How to Install Operator Cab Glass (Adhered Glass)...........................................................................................................3765 Remove and Install Air Conditioner Unit Assembly................................................................................................................3774 How to Remove Air Conditioner Unit Assembly.................................................................................................................3774 How to Install Air Conditioner Unit Assembly................................................................................................................3785 Remove and Install Operator Seat Assembly.......................................................................................................................3795 How to Remove Operator Seat Assembly........................................................................................................................3795 How to Install Operator Seat Assembly.......................................................................................................................3797 How to Remove and Install Seat Belt.............................................................................................................................3799 How to Remove Seat Belt.....................................................................................................................................3799 How to Install Seatbelt.....................................................................................................................................3799 Electrical System...................................................................................................................................................3801 Remove and Install Engine Controller Assembly...................................................................................................................3801 How to Remove Engine Controller Assembly....................................................................................................................3801 How to Install Engine Controller Assembly...................................................................................................................3803 Remove and Install Work Equipment Controller Assembly...........................................................................................................3806 How to Remove Work Equipment Controller Assembly............................................................................................................3806 How to Install Work Equipment Controller Assembly...........................................................................................................3807 Remove and Install Transmission Controller Assembly.............................................................................................................3810 How to Remove Transmission Controller Assembly..............................................................................................................3810 How to Install Transmission Controller Assembly.............................................................................................................3811 Remove and Install Monitor Controller Assembly..................................................................................................................3812 How to Remove Monitor Controller Assembly...................................................................................................................3812 How to Install Monitor Controller Assembly..................................................................................................................3814 Remove and Install Machine Monitor Assembly.....................................................................................................................3817 How to Remove Machine Monitor Assembly......................................................................................................................3817 How to Install Machine Monitor Assembly.....................................................................................................................3818 Remove and Install Mass Air Flow and Temperature Sensor.........................................................................................................3821 How to Remove Mass Air Flow and Temperature Sensor..........................................................................................................3821 How to Install Mass Air Flow and Temperature Sensor.........................................................................................................3822 Remove and Install KCCV Crankcase Pressure Sensor...............................................................................................................3823 How to Remove KCCV Crankcase Pressure Sensor................................................................................................................3823 How to Install KCCV Crankcase Pressure Sensor...............................................................................................................3824 Remove and Install KDPF Temperature Sensor......................................................................................................................3826 How to Remove KDPF Temperature Sensor.......................................................................................................................3826 How to Install KDPF Temperature Sensor......................................................................................................................3830 Remove and Install KDPF Differential Pressure Sensor............................................................................................................3835 How to Remove KDPF Differential Pressure Sensor.............................................................................................................3835 How to Install KDPF Differential Pressure Sensor............................................................................................................3839 Remove and Install SCR Temperature Sensor.......................................................................................................................3843 How to Remove SCR Temperature Sensor........................................................................................................................3843 How to Install SCR Temperature Sensor.......................................................................................................................3847 Remove and Install Ammonia Sensor...............................................................................................................................3852 How to Remove Ammonia Sensor................................................................................................................................3852 How to Install Ammonia Sensor...............................................................................................................................3855 Remove and Install SCR Outlet NOx Sensor........................................................................................................................3859 How to Remove SCR Outlet NOx Sensor.........................................................................................................................3859 How to Install SCR Outlet NOx Sensor........................................................................................................................3863 Remove and Install KOMTRAX Terminal Assembly....................................................................................................................3867 How to Remove KOMTRAX Terminal Assembly.....................................................................................................................3867 How to Install KOMTRAX Terminal Assembly....................................................................................................................3868 Remove and Install Gateway Function Controller Assembly.........................................................................................................3869 How to Remove Gateway Function Controller Assembly..........................................................................................................3869 How to Install Gateway Function Controller Assembly.........................................................................................................3870 Remove and Install Communication Terminal.......................................................................................................................3871 How to Remove Communication Terminal........................................................................................................................3871 How to Install Communication Terminal.......................................................................................................................3876 60 Maintenance Standard.................................................................................................................................................3883 Table of Contents...................................................................................................................................................3884 Abbreviation List...................................................................................................................................................3885 Engine and Cooling System...........................................................................................................................................3891 Maintenance Standard for Engine Mount...........................................................................................................................3891 Maintenance Standard for Brake and Cooling Fan Pump.............................................................................................................3892 Maintenance Standard for Servo Valve of Brake and Cooling Fan Pump..........................................................................................3894 Maintenance Standard for Cooling Fan Motor......................................................................................................................3895 Power Train.........................................................................................................................................................3897 Maintenance Standard for Drive Shaft............................................................................................................................3897 Maintenance Standard for Torque Converter.......................................................................................................................3898 Maintenance Standard for Lockup Clutch ECMV.....................................................................................................................3900 Maintenance Standard for Transmission...........................................................................................................................3901 Maintenance Standard for F, 1st Clutch......................................................................................................................3907 Maintenance Standard for R, 2nd Clutch......................................................................................................................3909 Maintenance Standard for 3rd, 4th Clutch....................................................................................................................3911 Maintenance Standard for Transmission Control Valve.............................................................................................................3913 Maintenance Standard for Forward and Reverse Clutch ECMV and 1st, 2nd Clutch ECMV...............................................................................3915 Maintenance Standard for 3rd, 4th Clutch ECMV...................................................................................................................3916 Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve....................................................................................3917 Maintenance Standard for Front Axle.............................................................................................................................3918 Maintenance Standard for Rear Axle..............................................................................................................................3920 Maintenance Standard for Front Conventional Differential........................................................................................................3922 Maintenance Standard for Rear Conventional Differential.........................................................................................................3928 Maintenance Standard for Front Limited Slip Differential........................................................................................................3934 Maintenance Standard for Rear Limited Slip Differential.........................................................................................................3938 Maintenance Standard for Final Drive............................................................................................................................3942 Steering System.....................................................................................................................................................3948 Maintenance Standard for Steering Column........................................................................................................................3948 Maintenance Standard for Steering Pump..........................................................................................................................3949 Maintenance Standard for Servo Valve of Steering Pump.......................................................................................................3952 Maintenance Standard for Steering Valve.........................................................................................................................3953 Maintenance Standard for Steering Cylinder......................................................................................................................3955 Maintenance Standard for Secondary Steering Pump................................................................................................................3957 Brake System........................................................................................................................................................3958 Maintenance Standard for Charge Valve...........................................................................................................................3958 Maintenance Standard for Brake Circuit Accumulator..............................................................................................................3960 Maintenance Standard for Slack Adjuster.........................................................................................................................3961 Maintenance Standard for Front Brake............................................................................................................................3962 Maintenance Standard for Rear Brake.............................................................................................................................3965 Maintenance Standard for Parking Brake..........................................................................................................................3968 Maintenance Standard for Parking Brake Solenoid Valve...........................................................................................................3970 Maintenance Standard for Flow Priority Valve....................................................................................................................3971 Maintenance Standard for Brake Cooling Pump.....................................................................................................................3972 Maintenance Standard for Brake Cooling Strainer.................................................................................................................3973 Undercarriage and Frame.............................................................................................................................................3974 Maintenance Standard for Frame, Axle Mount and Center Hinge Pin.................................................................................................3974 Hydraulic System....................................................................................................................................................3985 Maintenance Standard for Hydraulic Tank.........................................................................................................................3985 Maintenance Standard for Work Equipment Pump....................................................................................................................3987 Maintenance Standard for Power Train Charge Pump and Power Train Lubrication Pump...............................................................................3989 Maintenance Standard for Control Valve..........................................................................................................................3990 Maintenance Standard for Work Equipment Lock Solenoid Valve.....................................................................................................3999 Work Equipment......................................................................................................................................................4000 Maintenance Standard for Work Equipment Linkage.................................................................................................................4000 Maintenance Standard for Bucket.................................................................................................................................4004 Maintenance Standard for Lift Cylinder..........................................................................................................................4005 Maintenance Standard for Bucket Cylinder........................................................................................................................4006 80 Appendix.............................................................................................................................................................4007 Table of Contents...................................................................................................................................................4008 Precautions Before Work.............................................................................................................................................4010 Abbreviation List...................................................................................................................................................4011 Air Conditioner System..............................................................................................................................................4017 Precautions for Refrigerant.....................................................................................................................................4017 Air Conditioner Component.......................................................................................................................................4018 Specifications of Air Conditioner...............................................................................................................................4020 Structure and Function of Refrigeration Cycle...................................................................................................................4021 Outline of Refrigeration Cycle..................................................................................................................................4022 Component Parts of Air Conditioner System...........................................................................................................................4024 Air Conditioner Unit............................................................................................................................................4024 Configuration Diagram of Air Conditioner Unit...............................................................................................................4024 Function of Air Conditioner Unit............................................................................................................................4025 Component Parts of Air Conditioner Unit.........................................................................................................................4026 Function of Evaporator as Air Conditioner Unit Component....................................................................................................4026 Function of Inside Air Temperature Sensor as Air Conditioner Unit Component.................................................................................4026 Function of Blower Amplifier as Air Conditioner Unit Component..............................................................................................4027 Function of Blower OFF Relay as Air Conditioner Unit Component..............................................................................................4027 Function of Compressor Clutch Relay as Air Conditioner Unit Component.......................................................................................4027 Function of Heater Core as Air Conditioner Unit Component...................................................................................................4027 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component.................................................................................4027 Function of Servo Motor as Air Conditioner Unit Component...................................................................................................4027 Function of Expansion Valve as Air Conditioner Unit Component...............................................................................................4028 Function of Dual Pressure Switch............................................................................................................................4028 Air Conditioner Controller......................................................................................................................................4029 Structure of Air Conditioner Controller.....................................................................................................................4029 Compressor......................................................................................................................................................4030 Structure of Compressor.....................................................................................................................................4030 Specifications of Compressor................................................................................................................................4030 Function of Compressor......................................................................................................................................4030 Condenser.......................................................................................................................................................4031 Structure of Condenser......................................................................................................................................4031 Specifications of Condenser.................................................................................................................................4031 Function of Condenser.......................................................................................................................................4031 Receiver Drier..................................................................................................................................................4032 Structure of Receiver Dryer.................................................................................................................................4032 Specifications of Receiver Dryer............................................................................................................................4032 Function of Receiver Dryer..................................................................................................................................4032 Air Conditioner Related Sensors.................................................................................................................................4033 Function of Sunlight Sensor.................................................................................................................................4033 Function of Outside Air Temperature Sensor..................................................................................................................4033 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner.........................................................................................4034 Circuit Diagram and Configuration of Connector Pins of Air Conditioner..............................................................................................4036 System Diagram of Air Conditioner...................................................................................................................................4039 Input and Output Signals of Air Conditioner Controller..........................................................................................................4040 Function of Air Conditioner Controller......................................................................................................................4041 Locations of Air Conditioner Parts and Layout of Connectors.........................................................................................................4042 Examine Air Conditioner with Self-Diagnosis Function................................................................................................................4048 Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor.............................................................................4049 Examine Temperature Control Function................................................................................................................................4050 How to Examine Temperature Control Function.....................................................................................................................4050 Examine Vent (Mode) Changeover......................................................................................................................................4052 How to Examine Vent (Mode) Changeover...........................................................................................................................4052 Examine Fresh/Recirc Air Changeover.................................................................................................................................4054 How to Examine Fresh/Recirc Air Changeover......................................................................................................................4054 Examine Evaporator Temperature Sensor...............................................................................................................................4056 Examine Relay.......................................................................................................................................................4058 How to Examine Relay............................................................................................................................................4058 Air Conditioner Troubleshooting Chart 1.............................................................................................................................4060 Air Conditioner Troubleshooting Chart 2.............................................................................................................................4061 Information Shown in Troubleshooting Table..........................................................................................................................4064 Failure Code [879AKA]...............................................................................................................................................4065 Failure Code [879AKB]...............................................................................................................................................4067 Failure Code [879BKA]...............................................................................................................................................4069 Failure Code [879BKB]...............................................................................................................................................4071 Failure Code [879CKA]...............................................................................................................................................4073 Failure Code [879CKB]...............................................................................................................................................4075 Failure Code [879DKZ]...............................................................................................................................................4077 Failure Code [879EMC]...............................................................................................................................................4079 Failure Code [879FMC]...............................................................................................................................................4082 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)..........................................................................................4085 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)...........................................................................................4088 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)..................................................................................4091 Troubleshooting for Fresh/Recirc Air Changeover.....................................................................................................................4095 Troubleshooting by Gauge Pressure...................................................................................................................................4097 Connect Service Tool................................................................................................................................................4100 How to Connect Service Tool.....................................................................................................................................4101 Precautions for Disconnection and Connection of Air Conditioner Piping..............................................................................................4102 Handle Compressor Oil...............................................................................................................................................4104 90 Circuit Diagrams.....................................................................................................................................................4107 Table of Contents...................................................................................................................................................4108 Abbreviation List...................................................................................................................................................4111 Hydraulic Circuit Diagram...........................................................................................................................................4117 Symbols Used in Hydraulic Circuit Diagram.......................................................................................................................4117 Hydraulic Circuit Diagram (For AJSS Spec).......................................................................................................................4121 Hydraulic Circuit Diagram (For Steering Wheel Spec).............................................................................................................4123 Power Train Hydraulic Circuit Diagram...........................................................................................................................4125 Hydraulic Oil Pressure of Brake Cooling System..................................................................................................................4127 Hydraulic Auto-Greasing Diagram.................................................................................................................................4131 Electrical Circuit Diagram..........................................................................................................................................4133 Symbols Used in Electric Circuit Diagram........................................................................................................................4133 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (1/6).....................................................................................4137 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (2/6).....................................................................................4139 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (3/6).....................................................................................4141 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (4/6).....................................................................................4143 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (5/6).....................................................................................4145 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (6/6).....................................................................................4147 Electrical Circuit Diagram of Machine (Machine with gateway function controller) (1/6)..........................................................................4149 Electrical Circuit Diagram of Machine (Machine with gateway function controller) (2/6)..........................................................................4151 Electrical Circuit Diagram of Machine (Machine with gateway function controller) (3/6)..........................................................................4153 Electrical Circuit Diagram of Machine (Machine with gateway function controller) (4/6)..........................................................................4155 Electrical Circuit Diagram of Machine (Machine with gateway function controller) (5/6)..........................................................................4157 Electrical Circuit Diagram of Machine (Machine with gateway function controller) (6/6)..........................................................................4159 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (1/9).......................................................................4161 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (2/9).......................................................................4163 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (3/9).......................................................................4165 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (4/9).......................................................................4167 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (5/9).......................................................................4169 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (6/9).......................................................................4171 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (7/9).......................................................................4173 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (8/9).......................................................................4175 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (9/9).......................................................................4177 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (1/10)....................4179 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (2/10)....................4181 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (3/10)....................4183 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (4/10)....................4185 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (5/10)....................4187 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (6/10)....................4189 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (7/10)....................4191 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (8/10)....................4193 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (9/10)....................4195 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (10/10)...................4197 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (1/10).......................4199 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (2/10).......................4201 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (3/10).......................4203 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (4/10).......................4205 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (5/10).......................4207 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (6/10).......................4209 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (7/10).......................4211 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (8/10).......................4213 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (9/10).......................4215 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (10/10)......................4217 Electrical Circuit Diagram of Floor (For North America) (Machine with KOMTRAX Terminal) (1/8)...................................................................4219 Electrical Circuit Diagram of Floor (For North America) (Machine with KOMTRAX Terminal) (2/8)...................................................................4221 Electrical Circuit Diagram of Floor (For North America) (Machine with KOMTRAX Terminal) (3/8)...................................................................4223 Electrical Circuit Diagram of Floor (For North America) (Machine with KOMTRAX Terminal) (4/8)...................................................................4225 Electrical Circuit Diagram of Floor (For North America) (Machine with KOMTRAX Terminal) (5/8)...................................................................4227 Electrical Circuit Diagram of Floor (For North America) (Machine with KOMTRAX Terminal) (6/8)...................................................................4229 Electrical Circuit Diagram of Floor (For North America) (Machine with KOMTRAX Terminal) (7/8)...................................................................4231 Electrical Circuit Diagram of Floor (For North America) (Machine with KOMTRAX Terminal) (8/8)...................................................................4233 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (1/9).................4235 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (2/9).................4237 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (3/9).................4239 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (4/9).................4241 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (5/9).................4243 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (6/9).................4245 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (7/9).................4247 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (8/9).................4249 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (9/9).................4251 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (1/9)....................4253 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (2/9)....................4255 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (3/9)....................4257 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (4/9)....................4259 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (5/9)....................4261 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (6/9)....................4263 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (7/9)....................4265 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (8/9)....................4267 Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (9/9)....................4269 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (1/9)........................................................4271 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (2/9)........................................................4273 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (3/9)........................................................4275 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (4/9)........................................................4277 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (5/9)........................................................4279 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (6/9)........................................................4281 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (7/9)........................................................4283 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (8/9)........................................................4285 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (9/9)........................................................4287 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (1/10).....4289 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (2/10).....4291 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (3/10).....4293 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (4/10).....4295 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (5/10).....4297 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (6/10).....4299 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (7/10).....4301 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (8/10).....4303 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (9/10).....4305 Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (10/10)....4307 Electrical Circuit Diagram (Brake Cooling System)...............................................................................................................4309 Index....................................................................................................................................................................4311
DESCRIPTION:
KOMATSU WA480-8 WHEEL LOADER SHOP MANUAL SEN06663-09 – 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 30/12/24
