Komatsu WA480-8E0 Wheel Loader Shop Manual VENBM54000 – PDF DOWNLOAD

Description

Komatsu WA480-8E0 Wheel Loader Shop Manual VENBM54000 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA480-8E0 Wheel Loader Shop Manual VENBM54000 – PDF DOWNLOAD

Language : English
Pages :4094
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA480-8E0 Wheel Loader Shop Manual VENBM54000 – PDF DOWNLOAD

• SERIAL NUMBERS H53151 and up

00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 27
FOREWORD, SAFETY, BASIC INFORMATION 33
HOW TO READ THE SHOP MANUAL 33
SAFETY NOTICE FOR OPERATION 35
PRECAUTIONS TO PREVENT FIRE 43
ACTIONS IF FIRE OCCURS 45
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 46
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 47
PRECAUTIONS FOR DEF 48
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 48
PRECAUTIONS FOR ADDING 48
PRECAUTIONS FOR STORING 48
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 48
THE OTHER PRECAUTIONS 48
STORE AdBlue/DEF 49
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 50
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 53
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 60
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 62
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 63
PRACTICAL USE OF KOMTRAX 64
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 65
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 65
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 66
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 67
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 69
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 73
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 74
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 76
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 77
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 79
HOW TO READ ELECTRICAL WIRE CODE 80
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 84
STANDARD TIGHTENING TORQUE TABLE 87
CONVERSION TABLE 94
01 SPECIFICATIONS 99
CONTENTS 100
ABBREVIATION LIST 101
SPECIFICATIONS 107
SPECIFICATION DRAWING 107
SPECIFICATION DRAWING: WA480-8E0 107
SPECIFICATIONS 109
SPECIFICATIONS: WA480-8E0 109
WEIGHT TABLE 114
WEIGHT TABLE:WA480-8E0 114
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) 116
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 116
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION) 118
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 118
10 STRUCTURE AND FUNCTION 121
CONTENTS 122
ABBREVIATION LIST 127
UREA SCR SYSTEM 133
LAYOUT DRAWING OF UREA SCR SYSTEM 133
UREA SCR SYSTEM DIAGRAM 135
FUNCTION OF UREA SCR SYSTEM 136
FUNCTION OF AdBlue/DEF SYSTEM 136
INDUCEMENT STRATEGY 139
COMPONENT PARTS OF UREA SCR SYSTEM 153
AdBlue/DEF MIXING TUBE 153
SCR ASSEMBLY 154
AdBlue/DEF TANK 156
AdBlue/DEF PUMP 158
AdBlue/DEF INJECTOR 159
AdBlue/DEF HOSE 160
AdBlue/DEF TANK HEATING VALVE 161
BOOT-UP SYSTEM 162
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 162
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 164
SYSTEM OPERATING LAMP SYSTEM 166
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 166
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 166
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 166
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 167
BATTERY DISCONNECT SWITCH 169
FUNCTION OF BATTERY DISCONNECT SWITCH 169
PREHEATING SYSTEM 170
PREHEATING SYSTEM DIAGRAM 170
FUNCTION OF AUTOMATIC PREHEATING SYSTEM 170
OPERATION OF AUTOMATIC PREHEATING SYSTEM 170
FUNCTION OF MANUAL PREHEATING SYSTEM 171
OPERATION OF MANUAL PREHEATING SYSTEM 171
ENGINE SYSTEM 172
LAYOUT DRAWING OF ENGINE SYSTEM 172
FUNCTION OF ENGINE SYSTEM 173
ENGINE CONTROL SYSTEM 174
ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 174
ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 175
FUNCTION OF ENGINE CONTROL SYSTEM 175
OPERATION OF ENGINE CONTROL SYSTEM 178
ENGINE POWER MODE SELECTOR SYSTEM 180
ENGINE POWER MODE SELECTOR SYSTEM DIAGRAM 180
FUNCTION OF ENGINE POWER MODE SELECTOR SYSTEM 180
OPERATION OF ENGINE POWER MODE SELECTOR SYSTEM 180
AUTOMATIC IDLE STOP SYSTEM 182
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 182
COMPONENT PARTS OF ENGINE SYSTEM 183
VGT 183
EGR SYSTEM 186
EGR VALVE 188
EGR COOLER 190
KCCV SYSTEM 191
KCCV VENTILATOR 193
KDPF 195
COOLING SYSTEM 200
LAYOUT DRAWING OF COOLING SYSTEM 200
SPECIFICATIONS OF COOLING SYSTEM 201
COOLING FAN CONTROL SYSTEM 202
COOLING FAN CONTROL SYSTEM DIAGRAM 202
FUNCTION OF COOLING FAN CONTROL SYSTEM 202
COMPONENT PARTS OF COOLING SYSTEM 207
BRAKE AND COOLING FAN PUMP 207
COOLING FAN MOTOR 215
CONTROL SYSTEM 221
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 221
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 223
MACHINE MONITOR SYSTEM 225
MACHINE MONITOR SYSTEM DIAGRAM 225
FUNCTION OF MACHINE MONITOR SYSTEM 225
REARVIEW MONITOR SYSTEM 227
REARVIEW MONITOR SYSTEM DIAGRAM 227
FUNCTION OF REARVIEW MONITOR SYSTEM 227
KOMTRAX SYSTEM 228
KOMTRAX SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 228
SYSTEM DIAGRAM OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 228
FUNCTION OF KOMTRAX SYSTEM 229
LOAD METER SYSTEM 230
LOAD METER SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 230
LOAD METER SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 231
FUNCTION OF LOAD METER SYSTEM 231
COMPONENT PARTS OF CONTROL SYSTEM 237
MACHINE MONITOR 237
SWITCH PANEL 257
REARVIEW MONITOR 258
REARVIEW CAMERA 260
KOMTRAX TERMINAL 261
GATEWAY FUNCTION CONTROLLER 263
COMMUNICATION TERMINAL 266
TRANSMISSION CONTROLLER 268
WORK EQUIPMENT CONTROLLER 272
MONITOR CONTROLLER 276
CAN TERMINATING RESISTOR 281
ENGINE CONTROLLER 282
ACCELERATOR PEDAL 289
HYDRAULIC SYSTEM 291
LAYOUT DRAWING OF HYDRAULIC SYSTEM 291
CLSS 292
STRUCTURE OF CLSS 292
FUNCTION OF CLSS 293
WORK EQUIPMENT PUMP AND STEERING PUMP CONTROL SYSTEM 296
SWASH PLATE CONTROL FUNCTION OF WORK EQUIPMENT PUMP AND STEERING PUMP 296
PICKUP ASSISTANCE CONTROL FUNCTION WHEN ENGINE SPEED IS LOW 296
OVERHEAT PREVENTION FUNCTION OF WORK EQUIPMENT CIRCUIT 296
COMPONENT PARTS OF HYDRAULIC SYSTEM 297
HYDRAULIC TANK 297
WORK EQUIPMENT PUMP 300
STEERING PUMP 318
POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP 331
CONTROL VALVE 332
POWER TRAIN SYSTEM 367
LAYOUT DRAWING OF POWER TRAIN SYSTEM 367
OPERATION OF POWER TRAIN SYSTEM 370
TRANSMISSION CONTROL SYSTEM 371
TRANSMISSION CONTROL SYSTEM DIAGRAM 371
TRANSMISSION GEAR SHIFT CONTROL SYSTEM 373
ELECTRIC MODULATION FUNCTION SYSTEM DIAGRAM 373
ELECTRIC MODULATION FUNCTION 374
DISPLAY FUNCTION OF GEAR SHIFT 374
AUTOMATIC GEAR SHIFT FUNCTION 374
SHIFT HOLD FUNCTION 375
KICKDOWN FUNCTION 375
AUTOMATIC KICKDOWN FUNCTION 376
TORQUE CONVERTER LOCKUP FUNCTION 376
HUNTING PREVENTION FUNCTION 377
ADJUSTING FUNCTION OF TRANSMISSION INITIAL LEARNING AND ECMV CURRENT 377
SHIFT POINT CHANGING FUNCTION 377
4TH GEAR SPEED LIMITATION FUNCTION 377
TRANSMISSION PROTECTION FUNCTION 379
PROTECTION FUNCTION WHEN TRAVEL DIRECTION IS CHANGED 379
SHIFT DOWN PROTECTION FUNCTION 380
ENGINE OVERRUN PREVENTION FUNCTION 380
MAXIMUM SPEED LIMITATION FUNCTION 380
NEUTRALIZER FUNCTION 381
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION 382
TRANSMISSION CUT-OFF FUNCTION 384
COMPONENT PARTS OF POWER TRAIN SYSTEM 386
DRIVE SHAFT 386
TORQUE CONVERTER 388
LOCKUP CLUTCH ECMV 392
TRANSMISSION 395
TRANSMISSION CONTROL VALVE 412
FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND CLUTCH ECMV 415
3RD AND 4TH CLUTCH ECMV 420
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 426
AXLE 428
CONVENTIONAL DIFFERENTIAL 430
LIMITED SLIP DIFFERENTIAL 433
FINAL DRIVE 438
AJSS KNOB 440
COMBINATION SWITCH 441
SHIFT HOLD SWITCH 445
KICKDOWN SWITCH 446
WORK EQUIPMENT SYSTEM 447
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 447
WORK EQUIPMENT SYSTEM DIAGRAM 449
WORK EQUIPMENT CONTROL SYSTEM 451
WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE 451
WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION 451
WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM 452
WORK EQUIPMENT LEVER OPERATION FUNCTION 453
BUCKET PRIORITY CONTROL FUNCTION 453
BOOM STOP MODULATION FUNCTION 453
WORK EQUIPMENT NEUTRAL LOCK SYSTEM 455
WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM 455
FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM 455
REMOTE POSITIONER SYSTEM 457
REMOTE BUCKET POSITIONER SYSTEM DIAGRAM 457
FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM 457
REMOTE BOOM POSITIONER SYSTEM DIAGRAM 458
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM 458
BUCKET POSITIONER AND BOOM POSITIONER 462
STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER 462
AUTO-DIGGING SYSTEM 463
AUTO-DIGGING SYSTEM DIAGRAM 463
FUNCTION OF AUTO-DIGGING SYSTEM 463
ECSS 465
ECSS DIAGRAM 465
FUNCTION OF ECSS 465
OPERATION OF ECSS 465
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 467
WORK EQUIPMENT LOCK SOLENOID VALVE 467
PILOT CIRCUIT ACCUMULATOR 468
ECSS CIRCUIT ACCUMULATOR 469
WORK EQUIPMENT ELECTRIC LEVER 471
MULTIFUNCTION MONO-LEVER 474
STEERING SYSTEM 475
LAYOUT DRAWING OF STEERING SYSTEM 475
SECONDARY STEERING SYSTEM 478
SECONDARY STEERING SYSTEM DIAGRAM 478
FUNCTION OF SECONDARY STEERING SYSTEM 478
AJSS 480
LAYOUT DRAWING OF AJSS 480
AJSS DIAGRAM 481
FUNCTION OF AJSS 482
NEUTRALIZER FUNCTION OF AJSS 483
NEUTRAL INTERLOCK FUNCTION OF AJSS 483
SPEED SENSING STEERING FUNCTION OF AJSS 484
TURN SIGNAL PILOT LAMP CONTROL FUNCTION OF AJSS 485
STEERING COLUMN 486
STRUCTURE OF STEERING COLUMN 486
COMPONENT PARTS OF STEERING SYSTEM 487
AJSS EPC VALVE 487
STEERING LOCK VALVE 488
ROTARY VALVE 489
ORBITROL VALVE 492
STOP VALVE 496
STEERING VALVE 497
SECONDARY STEERING PUMP 509
SECONDARY STEERING MOTOR 510
BRAKE SYSTEM 511
LAYOUT DRAWING OF BRAKE SYSTEM 511
LAYOUT DRAWING OF BRAKE COOLING SYSTEM 512
PARKING BRAKE CONTROL SYSTEM 516
PARKING BRAKE CONTROL SYSTEM DIAGRAM 516
OPERATION OF PARKING BRAKE CONTROL SYSTEM 516
BRAKE COOLING CONTROL SYSTEM 518
BRAKE COOLING CONTROL SYSTEM DIAGRAM 518
FUNCTION OF BRAKE COOLING CONTROL SYSTEM 520
COMPONENT PARTS OF BRAKE SYSTEM 521
CHARGE VALVE 521
PARKING BRAKE SOLENOID VALVE 526
PARKING BRAKE EMERGENCY RELEASE VALVE 528
BRAKE CIRCUIT ACCUMULATOR 529
BRAKE VALVE 531
SLACK ADJUSTER 535
BRAKE 537
PARKING BRAKE 540
FLOW PRIORITY VALVE 542
BRAKE COOLING MOTOR 544
BRAKE COOLING PUMP 545
BRAKE COOLING PUMP MOTOR 546
BRAKE COOLING OIL COOLER 547
BRAKE COOLING FAN 549
MANUAL TYPE VALVE 549
AUTO-GREASING SYSTEM 551
LAYOUT DRAWING OF AUTO-GREASING SYSTEM 551
SPECIFICATIONS OF AUTO-GREASING SYSTEM 552
FUNCTION OF AUTO-GREASING SYSTEM 554
COMPONENT PARTS OF AUTO-GREASING SYSTEM 555
AUTO-GREASING PUMP 555
UNDERCARRIAGE AND FRAME 556
FRAME, AXLE MOUNT AND CENTER HINGE PIN 556
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 556
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 556
TIRE 558
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE 558
STRUCTURE OF RADIAL TIRE 558
FUNCTION OF RADIAL TIRE 559
STRUCTURE OF BIAS TIRE 559
FUNCTION OF BIAS TIRE 559
WORK EQUIPMENT 560
STRUCTURE OF WORK EQUIPMENT 560
STRUCTURE OF BUCKET 561
CAB AND ITS ATTACHMENTS 562
ROPS CAB 562
STRUCTURE OF ROPS CAB (MACHINE WITH KOMTRAX TERMINAL) 562
STRUCTURE OF ROPS CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 563
FUNCTION OF ROPS CAB 563
20 STANDARD VALUE TABLE 565
CONTENTS 566
ABBREVIATION LIST 567
STANDARD VALUE TABLE FOR ENGINE 573
STANDARD VALUE TABLE FOR ENGINE: WA480-8E0 573
STANDARD VALUE TABLE FOR MACHINE 577
STANDARD VALUE TABLE FOR MACHINE：WA480-8E0 577
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 602
30 TESTING AND ADJUSTING 607
CONTENTS 608
ABBREVIATION LIST 612
RELATED INFORMATION ON TESTING AND ADJUSTING 618
TOOLS FOR TESTING AND ADJUSTING 618
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 628
ENGINE AND COOLING SYSTEM 630
TEST ENGINE SPEED 630
METHOD FOR TESTING ENGINE SPEED 630
TEST BOOST PRESSURE 635
METHOD FOR TESTING BOOST PRESSURE 635
TESTING EXHAUST GAS TEMPERATURE 638
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 638
TEST EXHAUST GAS COLOR 640
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 640
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 641
TEST AND ADJUST VALVE CLEARANCE 643
METHOD FOR TESTING VALVE CLEARANCE 643
METHOD FOR ADJUSTING VALVE CLEARANCE 645
TEST COMPRESSION PRESSURE 646
METHOD FOR TESTING COMPRESSION PRESSURE 646
TEST BLOWBY PRESSURE 650
METHOD FOR TESTING BLOWBY PRESSURE 650
TEST ENGINE OIL PRESSURE 653
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 653
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 653
TEST EGR VALVE AND VGT OIL PRESSURE 655
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 655
TEST FUEL PRESSURE 656
METHOD FOR TESTING FUEL PRESSURE 656
TEST FUEL RETURN RATE AND LEAKAGE 658
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 659
BLEEDING AIR FROM FUEL SYSTEM 662
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 663
TEST FUEL CIRCUIT FOR LEAKAGE 664
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 664
HANDLE CYLINDER CUT-OUT MODE OPERATION 666
HANDLE NO-INJECTION CRANKING OPERATION 667
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 668
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 668
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 669
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 669
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 670
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 670
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 671
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 671
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 671
TEST ALTERNATOR BELT 673
METHOD FOR TESTING ALTERNATOR BELT 673
TEST AUTOMATIC TENSIONER 675
METHOD FOR TESTING AUTOMATIC TENSIONER 675
CLEAN FUEL DOSER 678
METHOD FOR CLEANING FUEL DOSER 678
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 680
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 680
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 687
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 687
TEST SCR RELATED FUNCTIONS 688
TEST AdBlue/DEF PUMP RAISED PRESSURE 692
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 695
TEST AdBlue/DEF LINE HEATER RELAY 1 700
TEST AdBlue/DEF LINE HEATER RELAY 2 704
TEST AdBlue/DEF PUMP HEATER RELAY 708
TEST AdBlue/DEF TANK HEATER VALVE 712
TEST SCR NOx REMOVAL EFFICIENCY 716
CLEAN AdBlue/DEF TANK 720
METHOD FOR CLEANING AdBlue/DEF TANK 720
CLEAN AdBlue/DEF PUMP 724
CLEAN AdBlue/DEF PUMP 724
POWER TRAIN 730
TEST AND ADJUST POWER TRAIN OIL PRESSURE 730
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 732
METHOD FOR ADJUSTING POWER TRAIN OIL PRESSURE 750
ADJUST TRANSMISSION INPUT SPEED SENSOR 752
METHOD FOR ADJUSTING TRANSMISSION INPUT SPEED SENSOR 752
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 754
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR 754
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 755
METHOD FOR FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 755
MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 758
METHOD FOR MOVING DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 759
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 762
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 762
STEERING SYSTEM 763
TEST STEERING WHEEL 763
METHOD FOR TESTING STEERING WHEEL 763
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 765
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE 765
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 769
BLEED AIR FROM STEERING CYLINDER CIRCUIT 771
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT 771
TEST AND ADJUST STEERING STOP VALVE 773
METHOD FOR TESTING STEERING STOP VALVE 773
METHOD FOR ADJUSTING STEERING STOP VALVE 773
BRAKE SYSTEM 774
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 774
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 774
TEST WHEEL BRAKE OIL PRESSURE 775
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE 775
TEST AND ADJUST ACCUMULATOR CHARGE PRESSURE 777
METHOD FOR TESTING ACCUMULATOR CHARGE PRESSURE 777
METHOD FOR ADJUSTING ACCUMULATOR CHARGE PRESSURE 778
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 779
METHOD FOR TESTING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 779
METHOD FOR CHARGING NITROGEN GAS IN BRAKE ACCUMULATOR 781
BLEED AIR FROM BRAKE CIRCUIT 787
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT 787
TEST BRAKING PERFORMANCE 791
METHOD FOR TESTING BRAKING PERFORMANCE 791
TEST BRAKE PEDAL 792
METHOD FOR TESTING BRAKE PEDAL 792
TEST AND ADJUST BRAKE PEDAL AND LINKAGE 793
METHOD FOR TESTING BRAKE PEDAL AND LINKAGE 793
METHOD FOR ADJUSTING BRAKE PEDAL AND LINKAGE 793
TEST LOWERING OF WHEEL BRAKE PRESSURE 794
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE 795
TEST WEAR OF WHEEL BRAKE DISC 797
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC 797
TEST PARKING BRAKE OIL PRESSURE 799
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE 799
TEST PARKING BRAKE PERFORMANCE 801
METHOD FOR TESTING PARKING BRAKE PERFORMANCE 801
RELEASE PARKING BRAKE MANUALLY 802
METHOD FOR RELEASING PARKING BRAKE MANUALLY 802
TEST WEAR AMOUNT OF PARKING BRAKE DISC 805
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC 805
HYDRAULIC SYSTEM 807
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 807
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 807
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE 809
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE 809
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE 813
TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE 815
METHOD FOR TESTING WORK EQUIPMENT EPC OIL PRESSURE 815
METHOD FOR ADJUSTING WORK EQUIPMENT EPC OIL PRESSURE 818
BLEED AIR FROM WORK EQUIPMENT CIRCUIT 820
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 820
TEST COOLING FAN SPEED 821
METHOD FOR TESTING COOLING FAN SPEED 821
TEST COOLING FAN CIRCUIT OIL PRESSURE 822
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 822
BLEED AIR FROM COOLING FAN CIRCUIT 825
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT 825
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS 827
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE 827
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS 829
WORK EQUIPMENT 833
TEST AND ADJUST BUCKET POTENTIOMETER LEVER 833
METHOD FOR TESTING BUCKET POTENTIOMETER LEVER 833
METHOD FOR ADJUSTING BUCKET POTENTIOMETER LEVER 833
TEST AND ADJUST BOOM POTENTIOMETER LEVER 835
METHOD FOR TESTING BOOM POTENTIOMETER LEVER 835
METHOD FOR ADJUSTING BOOM POTENTIOMETER LEVER 835
CAB AND ITS ATTACHMENTS 836
TEST DIRECTIONAL LEVER 836
METHOD FOR TESTING DIRECTIONAL LEVER 836
TEST WORK EQUIPMENT CONTROL LEVER 837
METHOD FOR TESTING WORK EQUIPMENT CONTROL LEVER 837
TEST AJSS LEVER (FOR AJSS SPEC) 840
METHOD FOR TESTING AJSS LEVER 840
TEST STEERING LOCK LEVER(FOR AJSS SPEC) 843
METHOD FOR TESTING OF STEERING LOCK LEVER 843
TEST AND ADJUST AJSS LEVER/FRAME ANGLE SENSOR (FOR AJSS SPEC) 844
METHOD FOR TESTING AJSS LEVER/FRAME ANGLE SENSOR 844
METHOD FOR ADJUSTING AJSS LEVER/FRAME ANGLE SENSOR 844
TEST AND AJUST STEERING STOPPER BOLT (FOR AJSS SPEC) 846
METHOD FOR TESTING STEERING STOPPER VALVE 846
METHOD FOR ADJUSTING STEERING STOPPER VALVE 846
ADJUST RATTLING OPERATOR’S SEAT 848
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 848
ELECTRICAL SYSTEM 849
SET AND ADJUST EACH EQUIPMENT 849
PREPARATION FOR TRANSMISSION ECMV CURRENT ADJUSTMENT 852
METHOD FOR ADJUSTING TRANSMISSION ECMV CURRENT 853
METHOD FOR SETTING AND RESETTING TRANSMISSION INITIAL LEARNING 856
SET AND OPERATE MACHINE MONITOR 861
OPERATOR MODE 865
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 865
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 865
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 866
CHECKING FUNCTION OF SERVICE METER AND ODOMETER 867
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 867
SERVICE MODE 871
METHOD FOR OPERATING SERVICE MODE 871
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 874
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 887
ABNORMALITY RECORD MENU 904
CHECK MAINTENANCE RECORD 909
MAINTENANCE MODE SETTING 911
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 916
DEFAULT MENU 918
DIAGNOSTIC TESTS MENU 934
ADJUSTMENT MENU 946
METHOD FOR PERFORMING NO-INJECTION CRANKING 984
KOMTRAX SETTINGS MENU 987
METHOD FOR DISPLAYING SERVICE MESSAGE 992
START UP KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) 994
STOP USING OF KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) 998
START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)1000
STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)1006
ADJUST REARVIEW CAMERA ANGLE1008
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE1008
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER1010
HANDLE BATTERY DISCONNECT SWITCH (MACHINE WITH KOMTRAX TERMINAL)1011
HANDLE BATTERY DISCONNECT SWITCH (MACHINE WITH GATEWAY FUNCTION CONTROLLER)1012
TEST DIODES1013
METHOD FOR TESTING DIODE USING DIGITAL TESTER1013
METHOD FOR TESTING DIODE USING ANALOG TESTER1013
AUTO-GREASING DEVICE1014
BLEED THE AIR OF AUTO-GREASING SYSTEM1014
METHOD FOR BLEEDING THE AIR OF AUTO-GREASING SYSTEM1014
CORREPONDENCE IN CASE OF GREASE LEAKAGE FROM OVER PRESSURE PROTECTION VALVE1017
CORREPONDING METHOD FOR GREASE LEAKAGE FROM OVER PRESSURE PROTECTION VALVE1017
CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES1018
METHOD FOR CHANGING THE LUBRICATION TIME AND LUBRICATION INTERVAL TIMES1019
Pm CLINIC1021
Pm CLINIC SERVICE1021
Pm CLINIC CHECK SHEET: WA480-8E01024
40 TROUBLESHOOTING1035
CONTENTS1036
ABBREVIATION LIST1050
RELATED INFORMATION ON TROUBLESHOOTING1056
GENERAL TROUBLESHOOTING POINTS1056
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM1057
SEQUENCE OF EVENTS IN TROUBLESHOOTING1069
CHECKS BEFORE TROUBLESHOOTING1071
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING1073
WALK-AROUND CHECK1073
TESTING IN ACCORDANCE WITH TESTING PROCEDURE1075
CHECK FUEL LEVEL AND TYPE1075
CHECK IMPURE INGREDIENT IN FUEL1075
CHECK AdBule/DEF LEVEL AND TYPE1076
CHECK FUEL PREFILTER1076
CHECK MAIN FILTER1078
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE1079
CHECK COOLANT LEVEL (RESERVOIR TANK)1079
CHECK CLOGGING OF AIR CLEANER1080
OUTER ELEMENT – CLEAN1081
REPLACE ELEMENT1083
CHECK HYDRAULIC OIL LEVEL1084
CHECK HYDRAULIC OIL STRAINER1085
CHECK HYDRAULIC FILTER1086
CHECK OIL LEVEL IN TRANSMISSION CASE1087
CHECK OIL LEVEL IN FRONT AXLE CASE1089
CHECK OIL LEVEL IN REAR AXLE CASE1090
BLEED AIR FROM FUEL SYSTEM1090
BLEED AIR FROM HYDRAULIC SYSTEM1090
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod1090
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION1096
PROCEDURE FOR TESTING AND TROUBLESHOOTING1109
SYMPTOM AND TROUBLESHOOTING NUMBERS1111
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE1116
CONNECTORS LIST AND LAYOUT(MACHINE WITH KOMTRAX TERMINAL)1118
CONNECTORS LIST AND LAYOUT(MACHINE WITH GATEWAY FUNCTION CONTROLLER)1145
CONNECTOR CONTACT IDENTIFICATION1172
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE1212
FUSE LOCATION TABLE(MACHINE WITH KOMTRAX TERMINAL)1218
FUSE LOCATION TABLE(MACHINE WITH GATEWAY FUNCTION CONTROLLER)1222
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)1226
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR1230
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT1232
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])1238
FAILURE CODES TABLE1240
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)1263
FAILURE CODE [1500L0]1263
FAILURE CODE [15SAL1]1264
FAILURE CODE [15SALH]1266
FAILURE CODE [15SBL1]1268
FAILURE CODE [15SBLH]1270
FAILURE CODE [15SEL1]1272
FAILURE CODE [15SELH]1274
FAILURE CODE [15SFL1]1276
FAILURE CODE [15SFLH]1278
FAILURE CODE [15SGL1]1280
FAILURE CODE [15SGLH]1282
FAILURE CODE [15SHL1]1284
FAILURE CODE [15SHLH]1286
FAILURE CODE [2F00MA]1289
FAILURE CODE [2F00MB]1293
FAILURE CODE [2G42ZG]1296
FAILURE CODE [2G43ZG]1298
FAILURE CODE [879AKA]1300
FAILURE CODE [879AKB]1302
FAILURE CODE [879BKA]1304
FAILURE CODE [879BKB]1306
FAILURE CODE [879CKA]1308
FAILURE CODE [879CKB]1310
FAILURE CODE [879DKZ]1312
FAILURE CODE [879EMC]1314
FAILURE CODE [879FMC]1317
FAILURE CODE [989A00]1320
FAILURE CODE [989L00]1321
FAILURE CODE [989M00]1322
FAILURE CODE [989N00]1323
FAILURE CODE [A1U0N3]1324
FAILURE CODE [A1U0N4]1326
FAILURE CODE [AA10NX]1328
FAILURE CODE [AB00KE]1330
FAILURE CODE [AB00KY]1332
FAILURE CODE [AQ10N3]1334
FAILURE CODE [AS00N3]1336
FAILURE CODE [AS00R2]1338
FAILURE CODE [AS00R3]1339
FAILURE CODE [AS00R4]1340
FAILURE CODE [AS00R5]1341
FAILURE CODE [AS00R6]1342
FAILURE CODE [AS00ZK]1343
FAILURE CODE [AS10KM]1344
FAILURE CODE [AS10NR]1345
FAILURE CODE [AS10NT]1346
FAILURE CODE [B@BAZG]1347
FAILURE CODE [B@BAZK]1348
FAILURE CODE [B@BCNS]1350
FAILURE CODE [B@BCQA]1351
FAILURE CODE [B@BCZK]1353
FAILURE CODE [B@C7NS]1355
FAILURE CODE [B@CENS]1357
FAILURE CODE [B@HANS]1358
FAILURE CODE [CA115]1359
FAILURE CODE [CA122]1360
FAILURE CODE [CA123]1362
FAILURE CODE [CA131]1364
FAILURE CODE [CA132]1366
FAILURE CODE [CA135]1369
FAILURE CODE [CA141]1371
FAILURE CODE [CA144]1373
FAILURE CODE [CA145]1375
FAILURE CODE [CA153]1377
FAILURE CODE [CA154]1380
FAILURE CODE [CA187]1383
FAILURE CODE [CA221]1385
FAILURE CODE [CA222]1387
FAILURE CODE [CA227]1389
FAILURE CODE [CA234]1390
FAILURE CODE [CA238]1391
FAILURE CODE [CA239]1393
FAILURE CODE [CA249]1395
FAILURE CODE [CA256]1397
FAILURE CODE [CA271]1399
FAILURE CODE [CA272]1401
FAILURE CODE [CA273]1402
FAILURE CODE [CA274]1404
FAILURE CODE [CA322]1405
FAILURE CODE [CA323]1407
FAILURE CODE [CA324]1409
FAILURE CODE [CA325]1411
FAILURE CODE [CA331]1413
FAILURE CODE [CA332]1415
FAILURE CODE [CA343]1417
FAILURE CODE [CA351]1418
FAILURE CODE [CA352]1419
FAILURE CODE [CA356]1422
FAILURE CODE [CA357]1424
FAILURE CODE [CA386]1426
FAILURE CODE [CA431]1427
FAILURE CODE [CA432]1430
FAILURE CODE [CA441]1434
FAILURE CODE [CA442]1436
FAILURE CODE [CA449]1437
FAILURE CODE [CA451]1438
FAILURE CODE [CA452]1440
FAILURE CODE [CA515]1442
FAILURE CODE [CA516]1444
FAILURE CODE [CA553]1446
FAILURE CODE [CA555]1447
FAILURE CODE [CA556]1448
FAILURE CODE [CA559]1449
FAILURE CODE [CA595]1454
FAILURE CODE [CA687]1455
FAILURE CODE [CA689]1457
FAILURE CODE [CA691]1459
FAILURE CODE [CA692]1461
FAILURE CODE [CA697]1463
FAILURE CODE [CA698]1464
FAILURE CODE [CA731]1465
FAILURE CODE [CA778]1466
FAILURE CODE [CA1117]1469
FAILURE CODE [CA1664]1470
FAILURE CODE [CA1669]1473
FAILURE CODE [CA1673]1474
FAILURE CODE [CA1677]1475
FAILURE CODE [CA1678]1476
FAILURE CODE [CA1682]1477
FAILURE CODE [CA1683]1482
FAILURE CODE [CA1684]1484
FAILURE CODE [CA1686]1486
FAILURE CODE [CA1691]1487
FAILURE CODE [CA1694]1490
FAILURE CODE [CA1695]1492
FAILURE CODE [CA1696]1493
FAILURE CODE [CA1712]1495
FAILURE CODE [CA1713]1498
FAILURE CODE [CA1714]1500
FAILURE CODE [CA1715]1501
FAILURE CODE [CA1776]1502
FAILURE CODE [CA1777]1505
FAILURE CODE [CA1843]1508
FAILURE CODE [CA1844]1510
FAILURE CODE [CA1879]1513
FAILURE CODE [CA1881]1516
FAILURE CODE [CA1883]1518
FAILURE CODE [CA1885]1522
FAILURE CODE [CA1887]1524
FAILURE CODE [CA1921]1526
FAILURE CODE [CA1922]1529
FAILURE CODE [CA1923]1534
FAILURE CODE [CA1924]1536
FAILURE CODE [CA1925]1538
FAILURE CODE [CA1927]1540
FAILURE CODE [CA1928]1542
FAILURE CODE [CA1942]1544
FAILURE CODE [CA1963]1545
FAILURE CODE [CA1977]1549
FAILURE CODE [CA1993]1552
FAILURE CODE [CA2185]1555
FAILURE CODE [CA2186]1557
FAILURE CODE [CA2249]1559
FAILURE CODE [CA2265]1560
FAILURE CODE [CA2266]1562
FAILURE CODE [CA2271]1565
FAILURE CODE [CA2272]1567
FAILURE CODE [CA2349]1569
FAILURE CODE [CA2353]1571
FAILURE CODE [CA2357]1573
FAILURE CODE [CA2381]1574
FAILURE CODE [CA2382]1576
FAILURE CODE [CA2383]1578
FAILURE CODE [CA2386]1580
FAILURE CODE [CA2387]1582
FAILURE CODE [CA2555]1583
FAILURE CODE [CA2556]1585
FAILURE CODE [CA2637]1587
FAILURE CODE [CA2639]1589
FAILURE CODE [CA2732]1592
FAILURE CODE [CA2733]1594
FAILURE CODE [CA2741]1596
FAILURE CODE [CA2765]1597
FAILURE CODE [CA2771]1598
FAILURE CODE [CA2777]1604
FAILURE CODE [CA2878]1607
FAILURE CODE [CA2881]1610
FAILURE CODE [CA2976]1613
FAILURE CODE [CA3133]1615
FAILURE CODE [CA3134]1617
FAILURE CODE [CA3135]1619
FAILURE CODE [CA3142]1623
FAILURE CODE [CA3143]1624
FAILURE CODE [CA3144]1625
FAILURE CODE [CA3146]1628
FAILURE CODE [CA3147]1629
FAILURE CODE [CA3148]1630
FAILURE CODE [CA3151]1632
FAILURE CODE [CA3165]1638
FAILURE CODE [CA3167]1640
FAILURE CODE [CA3229]1643
FAILURE CODE [CA3231]1645
FAILURE CODE [CA3232]1647
FAILURE CODE [CA3235]1651
FAILURE CODE [CA3239]1653
FAILURE CODE [CA3241]1656
FAILURE CODE [CA3242]1659
FAILURE CODE [CA3251]1662
FAILURE CODE [CA3253]1664
FAILURE CODE [CA3254]1667
FAILURE CODE [CA3255]1670
FAILURE CODE [CA3256]1674
FAILURE CODE [CA3311]1676
FAILURE CODE [CA3312]1678
FAILURE CODE [CA3313]1681
FAILURE CODE [CA3314]1682
FAILURE CODE [CA3315]1683
FAILURE CODE [CA3316]1686
FAILURE CODE [CA3317]1687
FAILURE CODE [CA3318]1688
FAILURE CODE [CA3319]1691
FAILURE CODE [CA3321]1692
FAILURE CODE [CA3322]1694
FAILURE CODE [CA3419]1697
FAILURE CODE [CA3421]1699
FAILURE CODE [CA3497]1701
FAILURE CODE [CA3498]1702
FAILURE CODE [CA3543]1703
FAILURE CODE [CA3545]1710
FAILURE CODE [CA3547]1712
FAILURE CODE [CA3558]1713
FAILURE CODE [CA3559]1715
FAILURE CODE [CA3562]1717
FAILURE CODE [CA3563]1719
FAILURE CODE [CA3567]1722
FAILURE CODE [CA3568]1725
FAILURE CODE [CA3571]1731
FAILURE CODE [CA3572]1733
FAILURE CODE [CA3574]1735
FAILURE CODE [CA3575]1738
FAILURE CODE [CA3577]1740
FAILURE CODE [CA3578]1742
FAILURE CODE [CA3582]1744
FAILURE CODE [CA3583]1752
FAILURE CODE [CA3596]1754
FAILURE CODE [CA3649]1757
FAILURE CODE [CA3681]1759
FAILURE CODE [CA3682]1764
FAILURE CODE [CA3713]1770
FAILURE CODE [CA3717]1773
FAILURE CODE [CA3718]1774
FAILURE CODE [CA3725]1775
FAILURE CODE [CA3748]1778
FAILURE CODE [CA3751]1781
FAILURE CODE [CA3755]1783
FAILURE CODE [CA3866]1785
FAILURE CODE [CA3867]1789
FAILURE CODE [CA3868]1792
FAILURE CODE [CA3899]1796
FAILURE CODE [CA3911]1798
FAILURE CODE [CA3912]1802
FAILURE CODE [CA3932]1804
FAILURE CODE [CA3933]1806
FAILURE CODE [CA3934]1808
FAILURE CODE [CA3935]1811
FAILURE CODE [CA3936]1813
FAILURE CODE [CA4151]1815
FAILURE CODE [CA4152]1819
FAILURE CODE [CA4155]1823
FAILURE CODE [CA4156]1825
FAILURE CODE [CA4157]1828
FAILURE CODE [CA4158]1830
FAILURE CODE [CA4159]1831
FAILURE CODE [CA4161]1832
FAILURE CODE [CA4162]1835
FAILURE CODE [CA4163]1838
FAILURE CODE [CA4164]1840
FAILURE CODE [CA4165]1842
FAILURE CODE [CA4166]1844
FAILURE CODE [CA4168]1846
FAILURE CODE [CA4169]1849
FAILURE CODE [CA4171]1851
FAILURE CODE [CA4249]1854
FAILURE CODE [CA4251]1856
FAILURE CODE [CA4259]1858
FAILURE CODE [CA4261]1861
FAILURE CODE [CA4277]1864
FAILURE CODE [CA4281]1868
FAILURE CODE [CA4459]1871
FAILURE CODE [CA4461]1874
FAILURE CODE [CA4658]1877
FAILURE CODE [CA4731]1881
FAILURE CODE [CA4732]1882
FAILURE CODE [CA4739]1883
FAILURE CODE [CA4768]1884
FAILURE CODE [CA4769]1886
FAILURE CODE [CA4842]1889
FAILURE CODE [CA4952] (MACHINE WITH KOMTRAX TERMINAL)1893
FAILURE CODE [CA4952] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)1895
FAILURE CODE [CA5115]1897
FAILURE CODE [CA5179]1900
FAILURE CODE [CA5181]1902
FAILURE CODE [CA5383]1904
FAILURE CODE [D150KA]1906
FAILURE CODE [D150KB]1908
FAILURE CODE [D150KY]1910
FAILURE CODE [D160KA]1912
FAILURE CODE [D160KB]1914
FAILURE CODE [D160KY]1916
FAILURE CODE [D191KA]1918
FAILURE CODE [D191KB]1921
FAILURE CODE [D191KY]1924
FAILURE CODE [D192KA]1926
FAILURE CODE [D192KB]1928
FAILURE CODE [D192KY]1930
FAILURE CODE [D19JKZ]1931
FAILURE CODE [D1E6KA]1933
FAILURE CODE [D1E6KB]1935
FAILURE CODE [D1E6KY]1937
FAILURE CODE [D5ZHKA]1939
FAILURE CODE [D5ZHKB]1941
FAILURE CODE [D5ZHKZ]1943
FAILURE CODE [D5ZHL6]1946
FAILURE CODE [D811MC] (MACHINE WITH KOMTRAX TERMINAL)1948
FAILURE CODE [D811MC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)1949
FAILURE CODE [D862KA] (MACHINE WITH KOMTRAX TERMINAL)1950
FAILURE CODE [D862KA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)1951
FAILURE CODE [D8ALKA] (MACHINE WITH KOMTRAX TERMINAL)1952
FAILURE CODE [D8ALKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)1954
FAILURE CODE [D8ALKB] (MACHINE WITH KOMTRAX TERMINAL)1956
FAILURE CODE [D8ALKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)1958
FAILURE CODE [D8AQK4] (MACHINE WITH KOMTRAX TERMINAL)1960
FAILURE CODE [D8AQK4] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)1961
FAILURE CODE [D8AQKR] (MACHINE WITH KOMTRAX TERMINAL)1962
FAILURE CODE [D8AQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)1964
FAILURE CODE [D8G1KT]1966
FAILURE CODE [D8G6KT]1967
FAILURE CODE [DAF0KT]1968
FAILURE CODE [DAF0MB]1969
FAILURE CODE [DAF0MC]1970
FAILURE CODE [DAF3KK]1971
FAILURE CODE [DAF8KB]1973
FAILURE CODE [DAFDKB]1975
FAILURE CODE [DAFGMC] (MACHINE WITH KOMTRAX TERMINAL)1977
FAILURE CODE [DAFGMC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)1978
FAILURE CODE [DAFLKA] (MACHINE WITH KOMTRAX TERMINAL)1979
FAILURE CODE [DAFLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)1981
FAILURE CODE [DAFLKB] (MACHINE WITH KOMTRAX TERMINAL)1983
FAILURE CODE [DAFLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)1985
FAILURE CODE [DAFQKR] (MACHINE WITH KOMTRAX TERMINAL)1987
FAILURE CODE [DAFQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)1988
FAILURE CODE [DAQ0KK]1989
FAILURE CODE [DAQ0KT]1992
FAILURE CODE [DAQ0MC]1993
FAILURE CODE [DAQ1KA]1994
FAILURE CODE [DAQ2KK]1996
FAILURE CODE [DAQ4KB]1999
FAILURE CODE [DAQ9KQ]2001
FAILURE CODE [DAQLKA] (MACHINE WITH KOMTRAX TERMINAL)2002
FAILURE CODE [DAQLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)2004
FAILURE CODE [DAQLKB] (MACHINE WITH KOMTRAX TERMINAL)2006
FAILURE CODE [DAQLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)2008
FAILURE CODE [DAQQKR]2010
FAILURE CODE [DAQRKR]2011
FAILURE CODE [DAQRMA]2012
FAILURE CODE [DAZ9KQ]2013
FAILURE CODE [DAZQKR]2014
FAILURE CODE [DB2QKR](MACHINE WITH KOMTRAX TERMINAL)2015
FAILURE CODE [DB2QKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER)2020
FAILURE CODE [DB2RKR]2025
FAILURE CODE [DB90KK](MACHINE WITH KOMTRAX TERMINAL)2031
FAILURE CODE [DB90KK](MACHINE WITH GATEWAY FUNCTION CONTROLLER)2034
FAILURE CODE [DB90KT]2037
FAILURE CODE [DB90MC]2038
FAILURE CODE [DB91KA]2039
FAILURE CODE [DB92KK](MACHINE WITH KOMTRAX TERMINAL)2041
FAILURE CODE [DB92KK](MACHINE WITH GATEWAY FUNCTION CONTROLLER)2044
FAILURE CODE [DB95KX]2047
FAILURE CODE [DB96KX]2050
FAILURE CODE [DB99KQ]2052
FAILURE CODE [DB9LKA](MACHINE WITH KOMTRAX TERMINAL)2053
FAILURE CODE [DB9LKA](MACHINE WITH GATEWAY FUNCTION CONTROLLER)2055
FAILURE CODE [DB9LKB](MACHINE WITH KOMTRAX TERMINAL)2057
FAILURE CODE [DB9LKB](MACHINE WITH GATEWAY FUNCTION CONTROLLER)2059
FAILURE CODE [DB9QKR]2061
FAILURE CODE [DB9RKR]2062
FAILURE CODE [DB9RMA]2063
FAILURE CODE [DBE5KX]2064
FAILURE CODE [DBE6KX]2066
FAILURE CODE [DD1ALD]2068
FAILURE CODE [DDAAL6]2070
FAILURE CODE [DDB6L4]2072
FAILURE CODE [DDD1LD]2075
FAILURE CODE [DDK3KA]2077
FAILURE CODE [DDK3KB]2080
FAILURE CODE [DDK4KA]2083
FAILURE CODE [DDK4KB]2086
FAILURE CODE [DDK5L4]2088
FAILURE CODE [DDK6KA]2090
FAILURE CODE [DDK6KB]2093
FAILURE CODE [DDKLKA]2096
FAILURE CODE [DDKLKB]2099
FAILURE CODE [DDNRKY]2101
FAILURE CODE [DDP5KA]2103
FAILURE CODE [DDT0L4]2105
FAILURE CODE [DDT4LD]2107
FAILURE CODE [DDT9LD]2109
FAILURE CODE [DDTALD]2111
FAILURE CODE [DDW9LD]2113
FAILURE CODE [DDWLLD]2115
FAILURE CODE [DF10KA]2117
FAILURE CODE [DF10KB]2120
FAILURE CODE [DGF1KA]2123
FAILURE CODE [DGF1KB]2125
FAILURE CODE [DGH2KX]2127
FAILURE CODE [DGR2KB]2129
FAILURE CODE [DGR2KZ]2131
FAILURE CODE [DGT1KA]2133
FAILURE CODE [DGT1KB]2135
FAILURE CODE [DH21KA]2137
FAILURE CODE [DH21KB]2140
FAILURE CODE [DHA4KA]2142
FAILURE CODE [DHAAMA]2144
FAILURE CODE [DHACMA]2146
FAILURE CODE [DHPCKX]2148
FAILURE CODE [DHPDKX]2151
FAILURE CODE [DHT1KX]2154
FAILURE CODE [DHT5KX]2157
FAILURE CODE [DHT7KX]2160
FAILURE CODE [DHT8KA]2163
FAILURE CODE [DHT8KB]2166
FAILURE CODE [DHT8ZG]2168
FAILURE CODE [DHUDKA]2169
FAILURE CODE [DHUDKB]2172
FAILURE CODE [DJF1KA]2174
FAILURE CODE [DK30KA]2176
FAILURE CODE [DK30KY]2178
FAILURE CODE [DK55KA]2180
FAILURE CODE [DK55KY]2183
FAILURE CODE [DK55L5]2185
FAILURE CODE [DK59KA]2186
FAILURE CODE [DK59KY]2190
FAILURE CODE [DK59L8]2194
FAILURE CODE [DK5AKA]2199
FAILURE CODE [DK5AKY]2203
FAILURE CODE [DK5BKA]2207
FAILURE CODE [DK5BKY]2211
FAILURE CODE [DK5BL8]2215
FAILURE CODE [DK5CKA]2220
FAILURE CODE [DK5CKY]2224
FAILURE CODE [DK5DKA]2228
FAILURE CODE [DK5DKY]2231
FAILURE CODE [DK5DL8]2234
FAILURE CODE [DK5EKA]2239
FAILURE CODE [DK5EKY]2242
FAILURE CODE [DKA0KA]2245
FAILURE CODE [DKA0KY]2248
FAILURE CODE [DKA0L0]2251
FAILURE CODE [DKA1KA]2254
FAILURE CODE [DKA1KY]2257
FAILURE CODE [DKD0KA]2260
FAILURE CODE [DKD0KY]2262
FAILURE CODE [DKD0L8]2264
FAILURE CODE [DLF1KA]2265
FAILURE CODE [DLF1LC]2267
FAILURE CODE [DLM3KA]2269
FAILURE CODE [DLM3LC]2271
FAILURE CODE [DLT3KA]2273
FAILURE CODE [DLT3LC]2275
FAILURE CODE [DPQ1KR]2277
FAILURE CODE [DPQ2KR]2280
FAILURE CODE [DPQ3KR]2283
FAILURE CODE [DSJ0KR]2286
FAILURE CODE [DT20KB]2289
FAILURE CODE [DT22KB]2291
FAILURE CODE [DT23KB]2293
FAILURE CODE [DV00KB]2295
FAILURE CODE [DW4PKA]2297
FAILURE CODE [DW4PKB]2299
FAILURE CODE [DW4PKY]2301
FAILURE CODE [DW4QKA]2303
FAILURE CODE [DW4QKB]2305
FAILURE CODE [DW4QKY]2307
FAILURE CODE [DW4RKA]2309
FAILURE CODE [DW4RKB]2311
FAILURE CODE [DW4RKY]2313
FAILURE CODE [DW4SKA]2315
FAILURE CODE [DW4SKB]2317
FAILURE CODE [DW4SKY]2319
FAILURE CODE [DW7BKA]2321
FAILURE CODE [DW7BKB]2323
FAILURE CODE [DW7BKY]2325
FAILURE CODE [DWM1KA]2327
FAILURE CODE [DWM1KB]2329
FAILURE CODE [DWM1KY]2331
FAILURE CODE [DWN6KA]2333
FAILURE CODE [DWN6KB]2335
FAILURE CODE [DWN6KY]2337
FAILURE CODE [DWN8KA]2339
FAILURE CODE [DWN8KB]2341
FAILURE CODE [DWN8KY]2343
FAILURE CODE [DX16KA]2345
FAILURE CODE [DX16KB]2347
FAILURE CODE [DX16KY]2349
FAILURE CODE [DXA1KA]2351
FAILURE CODE [DXA1KB]2353
FAILURE CODE [DXA1KY]2355
FAILURE CODE [DXANKA]2357
FAILURE CODE [DXANKB]2359
FAILURE CODE [DXANKY]2361
FAILURE CODE [DXF0KA]2363
FAILURE CODE [DXF0KB]2365
FAILURE CODE [DXF0KY]2367
FAILURE CODE [DXH1KA]2369
FAILURE CODE [DXH1KB]2371
FAILURE CODE [DXH1KY]2373
FAILURE CODE [DXH4KA]2375
FAILURE CODE [DXH4KB]2377
FAILURE CODE [DXH4KY]2379
FAILURE CODE [DXH5KA]2381
FAILURE CODE [DXH5KB]2383
FAILURE CODE [DXH5KY]2385
FAILURE CODE [DXH6KA]2387
FAILURE CODE [DXH6KB]2389
FAILURE CODE [DXH6KY]2391
FAILURE CODE [DXH7KA]2393
FAILURE CODE [DXH7KB]2395
FAILURE CODE [DXH7KY]2397
FAILURE CODE [DXH8KA]2399
FAILURE CODE [DXH8KB]2401
FAILURE CODE [DXH8KY]2403
FAILURE CODE [DXHHKA]2405
FAILURE CODE [DXHHKB]2407
FAILURE CODE [DXHHKY]2409
FAILURE CODE [DXHJKA]2411
FAILURE CODE [DXHJKB]2413
FAILURE CODE [DXHJKY]2415
FAILURE CODE [DXHKKA]2417
FAILURE CODE [DXHKKB]2419
FAILURE CODE [DXHKKY]2421
FAILURE CODE [DY30MA]2423
FAILURE CODE [DY30MC]2427
FAILURE CODE [DY30ME]2432
FAILURE CODE [F313KA]2434
FAILURE CODE [F313KB]2436
FAILURE CODE [F318KB]2437
FAILURE CODE [F318KY]2439
FAILURE CODE [LA00L3]2440
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)2441
ENGINE DOES NOT START (ENGINE DOES NOT CRANK)2441
MANUAL PREHEATING SYSTEM DOES NOT WORK2450
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK2453
WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP2456
ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING2458
LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING2461
BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)2464
LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY2467
METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL2470
NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL2473
LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL2477
NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY2479
2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION2482
SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL2485
SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY2488
AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY2489
REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS2492
REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY2495
REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED2498
NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL2502
AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP2504
RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP2506
PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION2508
WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP2512
WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP2513
FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL2514
TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP2516
INDICATION OF HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT2517
SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL2519
ALARM BUZZER DOES NOT SOUND2520
ALARM BUZZER DOES NOT STOP SOUNDING2522
KICKDOWN DOES NOT WORK WHEN KICKDOWN SWITCH IS TURNED ON2523
HOLD SWITCH DOES NOT WORK WHEN IT IS PRESSED2525
BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED2527
TRANSMISSION CUT-OFF MODE IS NOT SELECTED OR NOT RELEASED2531
TRANSMISSION CUT-OFF SETTING CANNOT BE RELEASED2533
DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED2535
ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE NORMALLY WHEN ENGINE POWER MODE SELECTOR SWITCH IS OPERATED2537
FLOW OF LOADER PUMP DOES NOT INCREASE FROM THE MINIMUM RATE2539
ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED2540
ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED (FOR AJSS SPEC)2542
HORN DOES NOT SOUND2544
HORN DOES NOT SOUND (FOR AJSS SPEC)2547
HORN DOES NOT STOP SOUNDING2550
NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS2553
NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS (FOR AJSS SPEC)2555
CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT2557
CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC)2561
CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2565
BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT2569
BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC)2573
BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2577
LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT2581
LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR AJSS SPEC)2583
LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2585
HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT2587
HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR AJSS SPEC)2589
HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2591
FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT2593
FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2598
REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT2603
REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2607
ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT2612
ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC)2615
TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT2618
TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC)2621
TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2625
HAZARD LAMP DOES NOT LIGHT UP OR GO OUT2628
HAZARD LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2633
BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED2637
BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT2641
BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND2644
FRONT WIPER DOES NOT OPERATE2646
FRONT WIPER DOES NOT OPERATE (FOR AJSS SPEC)2650
REAR WIPER DOES NOT OPERATE2654
REAR WIPER DOES NOT OPERATE (FOR AJSS SPEC)2657
FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY2660
FAN DOES NOT ROTATE IN REVERSE2663
FAN REMAINS ROTATED IN REVERSE2664
WINDOW WASHER DOES NOT OPERATE2665
WINDOW WASHER DOES NOT OPERATE (FOR AJSS SPEC)2668
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY2671
[FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP2672
[FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP2674
AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP2675
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)2677
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)2677
FAILURE MODE AND CAUSE TABLE2678
MACHINE DOES NOT START2698
LOCKUP IS NOT RELEASED2701
TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE2702
TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADABILITY IS LOW, OR GEAR SPEED DOES NOT SHIFT2703
LARGE SHOCK IS MADE WHEN MACHINE MOVES OFF OR GEAR IS SHIFTED2706
LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED2709
OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH2712
MACHINE DOES NOT TURN (FOR STEERING WHEEL SPEC)2715
MACHINE DOES NOT TURN (AJSS SPECIFICATION)2717
TURNING RESPONSE IS POOR (FOR STEERING WHEEL SPEC)2719
TURNING RESPONSE IS POOR (AJSS SPECIFICATION)2721
STEERING WHEEL IS HEAVY TO OPERATE2723
MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (FOR STEERING WHEEL SPEC)2724
MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (AJSS SPECIFICATION)2726
TURNING RADIUS DIFFERS BETWEEN RIGHT AND LEFT TURNS2728
WHEEL BRAKES DO NOT WORK OR ARE WEAK2729
WHEEL BRAKES ARE NOT RELEASED OR DRAG2731
PARKING BRAKE DOES NOT WORK OR IT IS WEAK2732
PARKING BRAKE IS NOT RELEASED OR DRAGS2733
BOOM DOES NOT RISE2735
BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE2737
RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT2739
LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND2740
HYDRAULIC DRIFT OF BOOM IS LARGE2742
BOOM MOVES UP AND DOWN DURING OPERATION2743
BUCKET DOES NOT TILT BACK2744
BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE2746
BUCKET DECELERATES DURING TILT-BACK OPERATION2748
BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND2749
HYDRAULIC DRIFT OF BUCKET IS LARGE2751
BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD)2752
BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE2753
WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS2754
LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS2755
WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES2758
ECSS (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES2759
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)2760
UNUSUAL NOISE IS HEARD FROM AROUND FAN2762
TROUBLESHOOTING OF ENGINE (S-MODE)2763
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)2763
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION2764
ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT2765
FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)2766
ENGINE STARTABILITY IS POOR2767
ENGINE DOES NOT PICK UP SMOOTHLY2769
ENGINE STOPS DURING OPERATION2771
ENGINE RUNS ROUGH OR IS UNSTABLE2773
ENGINE LACKS POWER2774
KDPF GETS CLOGGED IN A SHORT TIME2776
ENGINE OIL CONSUMPTION IS EXCESSIVE2778
OIL BECOMES CONTAMINATED QUICKLY2779
FUEL CONSUMPTION IS EXCESSIVE2780
OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2781
OIL PRESSURE DROPS2782
FUEL MIXES INTO ENGINE OIL2784
WATER MIXES INTO ENGINE OIL (MILKY)2785
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2786
UNUSUAL NOISE IS HEARD2787
VIBRATION IS EXCESSIVE2788
AIR CANNOT BE BLED FROM FUEL CIRCUIT2789
ACTIVE REGENERATION IS EXECUTED FREQUENTLY2790
ACTIVE REGENERATION TAKES TIME2792
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2794
AdBlue/DEF CONSUMPTION IS EXCESSIVE2795
THERE IS UNUSUAL SMELL (IRRITATING ODOR)2797
FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)2798
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM2799
OUTLINE OF FAILURE DISPLAY2799
TROUBLESHOOTING FOR FCS2800
TROUBLESHOOTING FOR AUTO-GREASING PUMP2801
REPLACEMENT OF PUMP ELEMENT2804
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM2805
REPLACEMENT OF AUTO-GREASING CONTROLLER2807
PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING2808
50 DISASSEMBLY AND ASSEMBLY2809
CONTENTS2810
ABBREVIATION LIST2815
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY2821
HOW TO READ THIS MANUAL2821
COATING MATERIALS LIST2823
SPECIAL TOOLS LIST2827
SKETCHES OF SPECIAL TOOLS2848
ENGINE AND COOLING SYSTEM2854
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2854
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY2855
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY2859
REMOVE AND INSTALL INJECTOR ASSEMBLY2864
METHOD FOR REMOVING INJECTOR ASSEMBLY2864
METHOD FOR INSTALLING INJECTOR ASSEMBLY2869
REMOVE AND INSTALL FUEL DOSER ASSEMBLY2875
METHOD FOR REMOVING FUEL DOSER ASSEMBLY2875
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY2876
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2879
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2880
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2891
REMOVE AND INSTALL EGR VALVE ASSEMBLY2908
METHOD FOR REMOVING EGR VALVE ASSEMBLY2908
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2908
REMOVE AND INSTALL EGR COOLER ASSEMBLY2910
METHOD FOR REMOVING EGR COOLER ASSEMBLY2910
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2912
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY2915
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY2915
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY2917
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT2919
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT2919
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT2921
REMOVE AND INSTALL ALTERNATOR BELT2924
METHOD FOR REMOVING ALTERNATOR BELT2924
METHOD FOR INSTALLING ALTERNATOR BELT2926
REMOVE AND INSTALL AUTOMATIC TENSIONER2929
METHOD FOR REMOVING AUTOMATIC TENSIONER2929
METHOD FOR INSTALLING AUTOMATIC TENSIONER2929
REMOVE AND INSTALL RADIATOR ASSEMBLY2930
METHOD FOR REMOVING RADIATOR ASSEMBLY2930
METHOD FOR INSTALLING RADIATOR ASSEMBLY2935
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY2940
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2941
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2945
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2948
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2948
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2950
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2953
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2953
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2957
REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY2961
METHOD FOR REMOVING POWER TRAIN OIL COOLER ASSEMBLY2962
METHOD FOR INSTALLING POWER TRAIN OIL COOLER ASSEMBLY2967
REMOVE AND INSTALL ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2973
METHOD FOR REMOVING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2974
METHOD FOR INSTALLING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2991
DISCONNECT AND CONNECT ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY3008
METHOD FOR DISCONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY3008
METHOD FOR CONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY3009
REMOVE AND INSTALL ENGINE FRONT OIL SEAL3011
METHOD FOR REMOVING ENGINE FRONT OIL SEAL3011
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL3013
REMOVE AND INSTALL ENGINE REAR OIL SEAL3016
METHOD FOR REMOVING ENGINE REAR OIL SEAL3017
METHOD FOR INSTALLING ENGINE REAR OIL SEAL3018
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY3024
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY3024
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY3031
REMOVE AND INSTALL FUEL TANK ASSEMBLY3037
METHOD FOR REMOVING FUEL TANK ASSEMBLY3037
METHOD FOR INSTALLING FUEL TANK ASSEMBLY3042
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY3046
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY3047
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY3051
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY3055
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY3056
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY3060
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR3064
REMOVE AdBlue/DEF TANK SENSOR3064
INSTALL AdBlue/DEF TANK SENSOR3065
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER3072
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER3072
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER3072
REMOVE AND INSTALL KDPF ASSEMBLY3074
METHOD FOR REMOVING KDPF ASSEMBLY3075
METHOD FOR INSTALLING KDPF ASSEMBLY3088
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY3103
METHOD FOR DISASSEMBLING KDPF ASSEMBLY3103
METHOD FOR ASSEMBLING KDPF ASSEMBLY3107
REMOVE AND INSTALL SCR ASSEMBLY3113
METHOD FOR REMOVING SCR ASSEMBLY3114
METHOD FOR INSTALLING SCR ASSEMBLY3124
REMOVE AND INSTALL KDPF, SCR ASSEMBLY3138
METHOD FOR REMOVING KDPF, SCR ASSEMBLY3139
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY3150
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY3161
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY3161
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY3166
REMOVE AND INSTALL KCCV ASSEMBLY3174
METHOD FOR REMOVING KCCV ASSEMBLY3174
METHOD FOR INSTALLING KCCV ASSEMBLY3175
REMOVE AND INSTALL VGT ASSEMBLY3177
METHOD FOR REMOVING VGT ASSEMBLY3178
METHOD FOR INSTALLING VGT ASSEMBLY3184
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE3190
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE3191
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE3198
REMOVE AND INSTALL AdBlue/DEF INJECTOR3207
METHOD FOR REMOVING AdBlue/DEF INJECTOR3207
METHOD FOR INSTALLING AdBlue/DEF INJECTOR3211
REMOVE AND INSTALL AdBlue/DEF PUMP3215
METHOD FOR REMOVING AdBlue/DEF PUMP3215
METHOD FOR INSTALLING AdBlue/DEF PUMP3218
REMOVE AND INSTALL AdBlue/DEF HOSE3221
METHOD FOR REMOVING AdBlue/DEF HOSE3222
METHOD FOR INSTALLING AdBlue/DEF HOSE3231
REMOVE AND INSTALL AIR CLEANER ASSEMBLY3242
METHOD FOR REMOVING AIR CLEANER ASSEMBLY3242
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY3243
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY3245
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY3245
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY3246
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY3249
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY3249
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY3250
POWER TRAIN3252
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY3252
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY3252
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY3257
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY3264
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY3266
METHOD FOR ASSEMBLING TRANSMISSION ASSEMBLY3284
DISASSEMBLE AND ASSEMBLE TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY3311
METHOD FOR DISASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY3312
METHOD FOR ASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY3328
REMOVE AND INSTALL FRONT AXLE ASSEMBLY3348
METHOD FOR REMOVING FRONT AXLE ASSEMBLY3348
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY3350
REMOVE AND INSTALL REAR AXLE ASSEMBLY3353
METHOD FOR REMOVING REAR AXLE ASSEMBLY3354
METHOD FOR INSTALLING REAR AXLE ASSEMBLY3360
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY3368
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY3369
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY3374
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY (SPECIFICATIONS OF 55m3 BUCKET)3382
DISASSEMBLE AXLE HOUSING ASSEMBLY (SPECIFICATIONS OF 55m3 BUCKET)3383
ASSEMBLE AXLE HOUSING ASSEMBLY (SPECIFICATIONS OF 55m3 BUCKET)3388
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY3396
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY3397
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY3406
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY (SPECIFICATIONS OF 55m3 BUCKET)3425
DISASSEMBLE DIFFERENTIAL ASSEMBLY (SPECIFICATIONS OF 55m3 BUCKET)3426
ASSEMBLE DIFFERENTIAL ASSEMBLY (SPECIFICATIONS OF 55m3 BUCKET)3436
STEERING SYSTEM3454
REMOVE AND INSTALL STEERING VALVE ASSEMBLY3454
METHOD FOR REMOVING STEERING VALVE ASSEMBLY3454
METHOD FOR INSTALLING STEERING VALVE ASSEMBLY3457
REMOVE AND INSTALL ROTARY VALVE ASSEMBLY (FOR AJSS SPEC)3460
METHOD FOR REMOVING ROTARY VALVE ASSEMBLY3460
METHOD FOR INSTALLING ROTARY VALVE ASSEMBLY3465
BRAKE SYSTEM3474
REMOVE AND INSTALL PARKING BRAKE DISC AND PLATE3474
METHOD FOR REMOVING PARKING BRAKE DISC AND PLATE3474
METHOD FOR INSTALLING PARKING BRAKE DISC AND PLATE3478
UNDERCARRIAGE AND FRAME3482
REMOVE AND INSTALL CENTER HINGE PIN3482
METHOD FOR REMOVING CENTER HINGE PIN3483
METHOD FOR INSTALLING CENTER HINGE PIN3488
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY3496
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY3496
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY3499
REMOVE AND INSTALL FULL-LENGTH FENDER ASSEMBLY3502
METHOD FOR REMOVING FULL-LENGTH FENDER ASSEMBLY3502
METHOD FOR INSTALLING FULL-LENGTH FENDER ASSEMBLY3503
HYDRAULIC SYSTEM3504
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY3504
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY3504
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY3510
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY3516
METHOD FOR REMOVING WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY3517
METHOD FOR INSTALLING WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY3519
REMOVE AND INSTALL STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY3522
METHOD FOR REMOVING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY3522
METHOD FOR INSTALLING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY3526
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY3529
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY3530
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY3533
WORK EQUIPMENT3538
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY3538
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY3539
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY3544
DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLY3552
METHOD FOR DISASSEMBLING HYDRAULIC CYLINDER ASSEMBLY3553
METHOD FOR ASSEMBLING HYDRAULIC CYLINDER ASSEMBLY3556
CAB AND ITS ATTACHMENTS3562
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY3562
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY3563
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY3569
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS)3576
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS)3576
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS)3577
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY3586
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY3586
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY3597
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY3607
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY3607
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY3609
REMOVE AND INSTALL SEAT BELT3611
METHOD FOR REMOVING SEAT BELT3611
METHOD FOR INSTALLING SEAT BELT3612
ELECTRICAL SYSTEM3613
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY3613
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY3613
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY3615
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY3618
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY3618
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY3620
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY3622
METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY3622
METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY3623
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY3624
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY3624
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY3626
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY3629
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY3629
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY3630
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR3633
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR3633
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR3634
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR3635
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR3635
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR3636
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR3638
METHOD FOR REMOVING KDPF TEMPERATURE SENSOR3638
METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR3643
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR3648
METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR3648
METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR3653
REMOVE AND INSTALL SCR TEMPERATURE SENSOR3657
METHOD FOR REMOVING SCR TEMPERATURE SENSOR3657
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR3662
REMOVE AND INSTALL AMMONIA SENSOR3666
METHOD FOR REMOVING AMMONIA SENSOR3666
METHOD FOR INSTALLING AMMONIA SENSOR3670
REMOVE AND INSTALL SCR OUTLET NOx SENSOR3674
METHOD FOR REMOVING SCR OUTLET NOx SENSOR3674
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR3679
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY3683
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY3683
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY3684
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY3685
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY3685
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY3686
REMOVE AND INSTALL COMMUNICATION TERMINAL3687
REMOVE COMMUNICATION TERMINAL3687
INSTALL COMMUNICATION TERMINAL3693
60 MAINTENANCE STANDARD3699
CONTENTS3700
ABBREVIATION LIST3702
ENGINE AND COOLING SYSTEM3708
MAINTENANCE STANDARD OF ENGINE MOUNT3708
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP3709
MAINTENANCE STANDARD OF SERVO VALVE OF BRAKE AND COOLING FAN PUMP3711
MAINTENANCE STANDARD OF COOLING FAN MOTOR3712
POWER TRAIN3714
MAINTENANCE STANDARD OF DRIVE SHAFT3714
MAINTENANCE STANDARD OF TORQUE CONVERTER3715
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV3717
MAINTENANCE STANDARD OF TRANSMISSION3718
MAINTENANCE STANDARD OF F, 1ST CLUTCH3724
MAINTENANCE STANDARD OF R, 2ND CLUTCH3726
MAINTENANCE STANDARD OF 3RD, 4TH CLUTCH3728
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE3730
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND CLUTCH ECMV3732
MAINTENANCE STANDARD OF 3RD, 4TH CLUTCH ECMV3733
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE3734
MAINTENANCE STANDARD OF FRONT AXLE3735
MAINTENANCE STANDARD OF REAR AXLE3737
MAINTENANCE STANDARD OF FRONT CONVENTIONAL DIFFERENTIAL3739
MAINTENANCE STANDARD OF REAR CONVENTIONAL DIFFERENTIAL3745
MAINTENANCE STANDARD OF FRONT LIMITED SLIP DIFFERENTIAL3751
MAINTENANCE STANDARD OF REAR LIMITED SLIP DIFFERENTIAL3755
MAINTENANCE STANDARD OF FINAL DRIVE3759
STEERING SYSTEM3765
MAINTENANCE STANDARD OF STEERING COLUMN3765
MAINTENANCE STANDARD OF STEERING PUMP3766
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING PUMP3769
MAINTENANCE STANDARD OF STEERING VALVE3770
MAINTENANCE STANDARD OF STEERING CYLINDER3772
MAINTENANCE STANDARD OF SECONDARY STEERING PUMP3774
BRAKE SYSTEM3775
MAINTENANCE STANDARD OF CHARGE VALVE3775
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR3777
MAINTENANCE STANDARD OF SLACK ADJUSTER3778
MAINTENANCE STANDARD OF FRONT BRAKE3779
MAINTENANCE STANDARD OF REAR BRAKE3782
MAINTENANCE STANDARD OF PARKING BRAKE3785
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE3787
MAINTENANCE STANDARD OF FLOW PRIORITY VALVE3788
MAINTENANCE STANDARD OF BRAKE COOLING PUMP3789
MAINTENANCE STANDARD OF BRAKE COOLING STRAINER3790
UNDERCARRIAGE AND FRAME3791
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN3791
HYDRAULIC SYSTEM3802
MAINTENANCE STANDARD OF HYDRAULIC TANK3802
MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP3804
MAINTENANCE STANDARD OF POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP3806
MAINTENANCE STANDARD OF CONTROL VALVE3807
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE3816
WORK EQUIPMENT3817
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE3817
MAINTENANCE STANDARD OF BUCKET3821
MAINTENANCE STANDARD OF LIFT CYLINDER3822
MAINTENANCE STANDARD OF BUCKET CYLINDER3823
80 APPENDIX3825
CONTENTS3826
ABBREVIATION LIST3828
AIR CONDITIONER SYSTEM3834
PRECAUTIONS FOR REFRIGERANT3834
AIR CONDITIONER COMPONENT3835
SPECIFICATIONS OF AIR CONDITIONER3837
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE3838
OUTLINE OF REFRIGERATION CYCLE3839
COMPONENT PARTS OF AIR CONDITIONER SYSTEM3841
AIR CONDITIONER UNIT3841
COMPONENT PARTS OF AIR CONDITIONER UNIT3843
AIR CONDITIONER CONTROLLER3846
COMPRESSOR3847
CONDENSER3848
RECEIVER DRIER3849
SENSORS FOR AIR CONDITIONER SYSTEM3850
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER3851
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER3853
AIR CONDITIONER SYSTEM DIAGRAM3856
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER3857
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS3859
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION3865
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR3866
CHECK TEMPERATURE CONTROL FUNCTION3867
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION3867
TEST VENT (MODE) CHANGEOVER3869
METHOD FOR TESTING VENT (MODE) CHANGEOVER3869
TESTING FRESH/RECIRC AIR CHANGEOVER3871
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER3871
TEST EVAPORATOR TEMPERATURE SENSOR3873
TEST RELAYS3875
METHOD FOR TESTING RELAYS3875
AIR CONDITIONER TROUBLESHOOTING CHART 13877
AIR CONDITIONER TROUBLESHOOTING CHART 23878
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE3881
FAILURE CODE [879AKA]3882
FAILURE CODE [879AKB]3884
FAILURE CODE [879BKA]3886
FAILURE CODE [879BKB]3888
FAILURE CODE [879CKA]3890
FAILURE CODE [879CKB]3892
FAILURE CODE [879DKZ]3894
FAILURE CODE [879EMC]3896
FAILURE CODE [879FMC]3899
TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)3902
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)3905
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)3908
TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER3912
TROUBLESHOOTING USING GAUGE PRESSURE3914
CONNECTION OF SERVICE TOOL3917
METHOD FOR CONNECTING SERVICE TOOL3918
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS3919
HANDLE COMPRESSOR OIL3921
KOMATSU SHORT LEVER JOYSTICK STEERING (K-SLS)3923
FUNCTION AND STRUCTURE3923
TESTING AND ADJUSTING3928
CONNECT TO JOYSTICK STEERING CONTROLLER3928
EC WS DESCRIPTION MENUS3928
TROUBLESHOOTING3934
E-01 JOYSTICK STEERING CANNOT BE ACTIVATED3934
E-02 MACHINE TURNS SLOWLY BY USING JOYSTICK STEERING3935
E-03 MACHINE STARTS TO TURN AFTER JSS IS ACTIVATED3935
E-04 MACHINE ONLY TURNS TO ONE SIDE3936
E-05 MACHINE DOES NOT DRIVE FORWARD OR BACKWARD WITH DIRECTIONAL SELECTOR (FNR) SWITCH ON LEFT ARM REST3937
90 CIRCUIT DIAGRAMS3939
CONTENTS3940
ABBREVIATION LIST3942
HYDRAULIC CIRCUIT DIAGRAM3948
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM3948
HYDRAULIC CIRCUIT DIAGRAM (FOR AJSS SPEC)3953
HYDRAULIC CIRCUIT DIAGRAM (FOR STEERING WHEEL SPEC)3955
HYDRAULIC CIRCUIT DIAGRAM (FOR K-SLS SPEC)3957
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM3959
HYDRAULIC OIL PRESSURE OF BRAKE COOLING SYSTEM3961
HYDRAULIC AUTO-GREASING DIAGRAM3963
ELECTRICAL CIRCUIT DIAGRAM3965
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM3965
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (1/6)3969
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (2/6)3971
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (3/6)3973
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (4/6)3975
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (5/6)3977
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (6/6)3979
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/6)3981
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/6)3983
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/6)3985
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/6)3987
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/6)3989
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/6)3991
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (1/9)3993
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (2/9)3995
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (3/9)3997
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (4/9)3999
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (5/9)4001
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (6/9)4003
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (7/9)4005
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (8/9)4007
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (9/9)4009
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/10)4011
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/10)4013
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/10)4015
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/10)4017
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/10)4019
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/10)4021
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/10)4023
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/10)4025
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (9/10)4027
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (10/10)4029
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (1/9)4031
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (2/9)4033
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (3/9)4035
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (4/9)4037
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (5/9)4039
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (6/9)4041
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (7/9)4043
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (8/9)4045
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (9/9)4047
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/10)4049
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/10)4051
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/10)4053
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/10)4055
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/10)4057
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/10)4059
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/10)4061
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/10)4063
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (9/10)4065
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (10/10)4067
ELECTRICAL CIRCUIT DIAGRAM (BRAKE COOLING SYSTEM)4069
INDEX4071

DESCRIPTION:

Komatsu WA480-8E0 Wheel Loader Shop Manual VENBM54000 – PDF DOWNLOAD

• SERIAL NUMBERS H53151 and up

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

G.B 04/01/25