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KOMATSU WA500-8E0 WHEEL LOADER SHOP MANUAL SEN06755-08 – PDF DOWNLOAD
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KOMATSU WA500-8E0 WHEEL LOADER SHOP MANUAL SEN06755-08 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA500-8E0 WHEEL LOADER SHOP MANUAL SEN06755-08 – PDF DOWNLOAD
Language : English
Pages : 4198
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU WA500-8E0 WHEEL LOADER SHOP MANUAL SEN06755-08 – 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: WA500-8E0.................................................................................................................................. 109 Specifications........................................................................................................................................................ 111 Specifications: WA500-8E0......................................................................................................................................... 111 Weight Table.......................................................................................................................................................... 116 Weight Table: WA500-8E0........................................................................................................................................... 116 Table of Fuel, Coolant, and Lubricants................................................................................................................................ 118 10 Structure and Function..................................................................................................................................................... 121 Table of Contents......................................................................................................................................................... 122 Abbreviation List......................................................................................................................................................... 127 Urea SCR System........................................................................................................................................................... 133 Layout Drawing of Urea SCR System..................................................................................................................................... 133 Urea SCR System Diagram............................................................................................................................................... 136 Function of Urea SCR System........................................................................................................................................... 137 Function of DEF System............................................................................................................................................ 137 Inducement Strategy............................................................................................................................................... 140 Component Parts of Urea SCR System.................................................................................................................................... 148 DEF Mixing Tube................................................................................................................................................... 148 SCR Assembly...................................................................................................................................................... 148 DEF Tank.......................................................................................................................................................... 151 DEF Pump.......................................................................................................................................................... 153 DEF Injector...................................................................................................................................................... 154 DEF Hose.......................................................................................................................................................... 155 DEF Tank Heating Valve............................................................................................................................................ 156 Boot-up System............................................................................................................................................................ 157 Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal)...................................................................................................... 157 Layout Drawing of Boot-up System (Machine with Gateway Function Controller)........................................................................................... 159 Layout Drawing of Boot-up System (For Emergency Engine Stop Switch Spec) (Machine with KOMTRAX Terminal).............................................................. 161 Layout Drawing of Boot-up System (For Emergency Engine Stop Switch Spec) (Machine with Gateway Function Controller)................................................... 163 System Operating Lamp System.......................................................................................................................................... 165 System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal).................................................................................... 165 System Diagram of System Operating Lamp System (Machine with Gateway Function Controller)......................................................................... 165 Function of System Operating Lamp System (Machine with KOMTRAX Terminal).......................................................................................... 165 Function of System Operating Lamp System (Machine with Gateway Function Controller)............................................................................... 166 Battery Disconnect Switch............................................................................................................................................. 168 Layout Drawing of Battery Disconnect Switch....................................................................................................................... 168 Function of Battery Disconnect Switch............................................................................................................................. 168 Preheating System..................................................................................................................................................... 170 System Diagram of Preheating System............................................................................................................................... 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 Shutdown Secondary Switch...................................................................................................................................... 172 Layout Drawing of Engine Shutdown Secondary Switch................................................................................................................ 172 Function of Engine Shutdown Secondary Switch...................................................................................................................... 172 Operation of Engine Shutdown Secondary Switch..................................................................................................................... 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................................................................................................................................. 178 Operation of Engine Control System................................................................................................................................ 181 Engine Power Mode Selector System..................................................................................................................................... 183 Engine Power Mode Selector System Diagram......................................................................................................................... 183 Function of Engine Power Mode Selector System..................................................................................................................... 183 Operation of Engine Power Mode Selector System.................................................................................................................... 183 Automatic Idle Stop System............................................................................................................................................ 184 Function of Automatic Idle Stop System............................................................................................................................ 184 RPM Set............................................................................................................................................................... 185 Function of RPM Set............................................................................................................................................... 185 Operation of RPM Set.............................................................................................................................................. 186 Component Parts of Engine System...................................................................................................................................... 189 Joint............................................................................................................................................................. 189 VGT............................................................................................................................................................... 189 EGR System........................................................................................................................................................ 193 EGR Valve......................................................................................................................................................... 195 EGR Cooler........................................................................................................................................................ 197 KCCV System....................................................................................................................................................... 199 KCCV Ventilator................................................................................................................................................... 201 KDPF.............................................................................................................................................................. 204 Cooling System............................................................................................................................................................ 208 Layout Drawing of Cooling System...................................................................................................................................... 208 Specifications of Cooling System.................................................................................................................................. 208 Cooling Fan Control System............................................................................................................................................ 210 System Diagram of Cooling Fan Control System...................................................................................................................... 210 Function of Cooling Fan Control System............................................................................................................................ 210 Component Parts of Cooling System..................................................................................................................................... 215 Brake and Cooling Fan Pump........................................................................................................................................ 215 Cooling Fan Motor................................................................................................................................................. 222 Control System............................................................................................................................................................ 229 Layout Drawing of Control System (Machine with KOMTRAX Terminal)...................................................................................................... 229 Layout Drawing of Control System (Machine with Gateway Function Controller)........................................................................................... 231 Machine Monitor System................................................................................................................................................ 233 System Diagram of Machine Monitor System.......................................................................................................................... 233 Function of Machine Monitor System................................................................................................................................ 233 Rearview Monitor System............................................................................................................................................... 235 System Diagram of Rearview Monitor System......................................................................................................................... 235 Function of Rearview Monitor System............................................................................................................................... 235 KOMTRAX System........................................................................................................................................................ 236 KOMTRAX System Diagram (Machine with KOMTRAX Terminal)............................................................................................................ 236 System Diagram of KOMTRAX System (Machine with Gateway Function Controller)....................................................................................... 236 Function of KOMTRAX System........................................................................................................................................ 237 Load Meter System..................................................................................................................................................... 238 Load Meter System Diagram (Machine with KOMTRAX Terminal)......................................................................................................... 238 Load Meter System Diagram (Machine with Gateway Function Controller).............................................................................................. 239 Function of Load Meter System..................................................................................................................................... 239 Component Parts of Control System..................................................................................................................................... 245 Machine Monitor................................................................................................................................................... 245 Switch Panel...................................................................................................................................................... 264 Rearview Monitor.................................................................................................................................................. 265 Rearview Camera................................................................................................................................................... 266 KOMTRAX Terminal.................................................................................................................................................. 267 Gateway Function Controller....................................................................................................................................... 269 Communication Terminal............................................................................................................................................ 272 Transmission Controller........................................................................................................................................... 274 Work Equipment Controller......................................................................................................................................... 278 Monitor Controller................................................................................................................................................ 282 CAN Terminating Resistor.......................................................................................................................................... 286 Engine Controller................................................................................................................................................. 287 Accelerator Pedal................................................................................................................................................. 293 Fuel Feed Pump.................................................................................................................................................... 295 Fuel Feed Pump Switch............................................................................................................................................. 296 Hydraulic System.......................................................................................................................................................... 298 Layout Drawing of Hydraulic System.................................................................................................................................... 298 CLSS.................................................................................................................................................................. 299 Structure of CLSS................................................................................................................................................. 299 Function of CLSS.................................................................................................................................................. 300 Work Equipment Pump Control System.................................................................................................................................... 303 Swash Plate Control Function of Work Equipment Pump............................................................................................................... 303 Pickup Assistance Control Function When Engine Speed is Low....................................................................................................... 303 Component Parts of Hydraulic System................................................................................................................................... 304 Hydraulic Tank.................................................................................................................................................... 304 Work Equipment Pump............................................................................................................................................... 307 Steering Pump..................................................................................................................................................... 325 Power Train Charge Duplex Pump.................................................................................................................................... 338 Control Valve..................................................................................................................................................... 339 Power Train System........................................................................................................................................................ 382 Layout Drawing of Power Train System.................................................................................................................................. 382 Operation of Power Train System....................................................................................................................................... 386 Transmission Control System........................................................................................................................................... 387 Transmission Control System Diagram............................................................................................................................... 387 Transmission Gear Shift Control System................................................................................................................................ 389 Electric Modulation Function System Diagram....................................................................................................................... 389 Electric Modulation Function...................................................................................................................................... 390 Gear Shift Display Function....................................................................................................................................... 390 Automatic Gear Shift Function..................................................................................................................................... 390 Shift Hold Function............................................................................................................................................... 391 Kickdown Function................................................................................................................................................. 391 Automatic Kickdown Function....................................................................................................................................... 392 Torque Converter Lockup Function.................................................................................................................................. 392 Hunting Prevention Function....................................................................................................................................... 393 Transmission Initial Learning and ECMV Current Adjustment Function................................................................................................ 393 Shift Point Changing Function..................................................................................................................................... 393 4th Gear Speed Limitation Function................................................................................................................................ 394 Transmission Protection Function...................................................................................................................................... 395 Protection Function When Travel Direction is Changed.............................................................................................................. 395 Shift Down Protection Function.................................................................................................................................... 395 Engine Overrun Prevention Function................................................................................................................................ 396 Maximum Speed Limitation Function................................................................................................................................. 396 Neutralizer Function.............................................................................................................................................. 397 Directional Selector Switch Control Function.......................................................................................................................... 398 Transmission Cut-off Function......................................................................................................................................... 400 Component Parts of Power Train System................................................................................................................................. 402 Drive Shaft....................................................................................................................................................... 402 Torque Converter.................................................................................................................................................. 405 Lockup Clutch ECMV................................................................................................................................................ 411 Transmission...................................................................................................................................................... 414 Transmission Control Valve........................................................................................................................................ 430 Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV........................................................................................................ 432 Transfer.......................................................................................................................................................... 437 Torque Converter Regulator Valve.................................................................................................................................. 439 Main Relief Valve, Torque Converter Relief Valve, and Main Flow Selector Valve.................................................................................... 441 Transmission Lubrication Relief Valve............................................................................................................................. 445 Power Train Oil Cooler............................................................................................................................................ 446 Axle.............................................................................................................................................................. 447 Conventional Differential......................................................................................................................................... 449 Limited Slip Differential......................................................................................................................................... 451 Final Drive....................................................................................................................................................... 457 AJSS Knob......................................................................................................................................................... 459 Combination Switch................................................................................................................................................ 460 Shift Hold Switch................................................................................................................................................. 463 Kickdown Switch................................................................................................................................................... 464 Work Equipment System..................................................................................................................................................... 465 Layout Drawing of Work Equipment System............................................................................................................................... 465 Work Equipment System Diagram (Applicable Machine: 90278 to 90960).................................................................................................... 467 Work Equipment System Diagram (Applicable Machine: 90961 and Up)...................................................................................................... 469 Work Equipment Control System......................................................................................................................................... 471 Work Equipment Speed Pattern Control Function by Work Equipment Lever Stroke...................................................................................... 471 Work Equipment Lever Detent Position and Work Equipment Startup Current Control Function.......................................................................... 472 Work Equipment Lever Operating Function System Diagram............................................................................................................ 473 Work Equipment Lever Operation Function........................................................................................................................... 474 Bucket Priority Control Function.................................................................................................................................. 474 Boom Stop Modulation Function..................................................................................................................................... 474 Work Equipment Neutral Lock System.................................................................................................................................... 476 Work Equipment Neutral Lock System Diagram........................................................................................................................ 476 Function of Work Equipment Neutral Lock System.................................................................................................................... 476 Remote Positioner System.............................................................................................................................................. 478 Remote Bucket Positioner System Diagram........................................................................................................................... 478 Function of Remote Bucket Positioner System....................................................................................................................... 478 Remote Boom Positioner System Diagram............................................................................................................................. 479 Function of Remote Boom Positioner System......................................................................................................................... 479 Bucket Positioner and Boom Positioner................................................................................................................................. 483 Structure of Bucket Positioner and Boom Positioner................................................................................................................ 483 Auto-Digging System................................................................................................................................................... 484 Auto-Digging System Diagram....................................................................................................................................... 484 Function of Auto-Digging System................................................................................................................................... 484 ECSS.................................................................................................................................................................. 486 ECSS Diagram...................................................................................................................................................... 486 Function of ECSS.................................................................................................................................................. 486 Operation of ECSS................................................................................................................................................. 486 Component Parts of Work Equipment System.............................................................................................................................. 488 Work Equipment Lock Solenoid Valve................................................................................................................................ 488 Pilot Circuit Accumulator......................................................................................................................................... 489 ECSS Circuit Accumulator.......................................................................................................................................... 490 Work Equipment Electric Lever..................................................................................................................................... 491 Electric Mono-Lever............................................................................................................................................... 494 Multifunction Mono-Lever.......................................................................................................................................... 498 Steering System........................................................................................................................................................... 499 Layout Drawing of Steering System..................................................................................................................................... 499 Secondary Steering System............................................................................................................................................. 501 Secondary Steering System Diagram................................................................................................................................. 501 Function of Secondary Steering System............................................................................................................................. 501 Joystick Steering System.............................................................................................................................................. 502 Layout Drawing of Joystick Steering System........................................................................................................................ 502 Function of Joystick Steering System.............................................................................................................................. 502 Joystick Control Function......................................................................................................................................... 503 Joystick Neutral Safety Function.................................................................................................................................. 506 Joystick Neutral Interlock Function............................................................................................................................... 506 Joystick Speed Sensing Steering Function.......................................................................................................................... 506 Joystick Hi/Lo Selector Function.................................................................................................................................. 507 AJSS.................................................................................................................................................................. 508 Layout Drawing of AJSS............................................................................................................................................ 508 AJSS System Diagram............................................................................................................................................... 509 Function of AJSS.................................................................................................................................................. 510 Neutralizer Function of AJSS...................................................................................................................................... 511 AJSS Neutral Interlock Function................................................................................................................................... 511 AJSS Speed Sensing Steering Function.............................................................................................................................. 512 AJSS Turn Signal Pilot Lamp Control Function...................................................................................................................... 513 Steering Column....................................................................................................................................................... 515 Structure of Steering Column...................................................................................................................................... 515 Component Parts of Steering System.................................................................................................................................... 516 AJSS EPC Valve.................................................................................................................................................... 516 Steering Lock Valve............................................................................................................................................... 517 Rotary Valve...................................................................................................................................................... 518 Orbitrol Valve.................................................................................................................................................... 521 Stop Valve........................................................................................................................................................ 525 Steering Valve.................................................................................................................................................... 526 Diverter Valve.................................................................................................................................................... 537 Secondary Steering Relief Valve................................................................................................................................... 541 Secondary Steering Pump........................................................................................................................................... 543 Joystick Knob..................................................................................................................................................... 544 Brake System.............................................................................................................................................................. 545 Layout Drawing of Brake System........................................................................................................................................ 545 Parking Brake Control System.......................................................................................................................................... 548 System Diagram of Parking Brake Control System.................................................................................................................... 548 Operation of Parking Brake Control System......................................................................................................................... 548 Component Parts of Brake System....................................................................................................................................... 550 Charge Valve...................................................................................................................................................... 550 Brake Circuit Accumulator......................................................................................................................................... 555 Parking Brake Solenoid Valve...................................................................................................................................... 556 Parking Brake Emergency Release Valve............................................................................................................................. 558 Brake Valve....................................................................................................................................................... 559 Slack Adjuster.................................................................................................................................................... 563 Brake............................................................................................................................................................. 565 Parking Brake..................................................................................................................................................... 567 Auto-Greasing System...................................................................................................................................................... 569 Layout Drawing of Auto-Greasing System................................................................................................................................ 569 Specifications of Auto-Greasing System................................................................................................................................ 570 Function of Auto-Greasing System...................................................................................................................................... 572 Auto-Greasing System.................................................................................................................................................. 573 Auto-Greasing Pump................................................................................................................................................ 573 Undercarriage and Frame................................................................................................................................................... 574 Frame, Axle Mount and Center Hinge Pin................................................................................................................................ 574 Structure of Frame, Axle Mount and Center Hinge Pin............................................................................................................... 574 Function of Frame, Axle Mount and Center Hinge Pin................................................................................................................ 575 Tires................................................................................................................................................................. 576 Features of Radial Tire When Compared with Bias Tire.............................................................................................................. 576 Structure of Radial Tire.......................................................................................................................................... 576 Function of Radial Tire........................................................................................................................................... 577 Structure of Bias Tire............................................................................................................................................ 577 Function of Bias Tire............................................................................................................................................. 577 Work Equipment............................................................................................................................................................ 578 Structure of Work Equipment........................................................................................................................................... 578 Structure of Bucket................................................................................................................................................... 579 Structure of Lubrication System for Work Equipment.................................................................................................................... 581 CAB Related Parts......................................................................................................................................................... 583 ROPS CAB.............................................................................................................................................................. 583 Structure of ROPS CAB (Machine with KOMTRAX Terminal)............................................................................................................. 583 Structure of ROPS CAB (Machine with Gateway Function Controller).................................................................................................. 584 Function of ROPS CAB.............................................................................................................................................. 584 20 Standard Value Table....................................................................................................................................................... 585 Table of Contents......................................................................................................................................................... 586 Abbreviation List......................................................................................................................................................... 587 Standard Value Table for Engine........................................................................................................................................... 593 Standard Value Table for Engine: WA500-8E0............................................................................................................................ 593 Standard Value Table for Machine.......................................................................................................................................... 596 Standard Value Table for Machine: WA500-8E0........................................................................................................................... 596 Machine Posture and Procedures to Measure Performance................................................................................................................. 617 30 Testing and Adjusting...................................................................................................................................................... 621 Table of Contents......................................................................................................................................................... 622 Precautions Before Work................................................................................................................................................... 626 Abbreviation List......................................................................................................................................................... 627 Related Information on Testing and Adjusting.............................................................................................................................. 633 Differences In Machine Monitor Symbols................................................................................................................................ 633 Tools for Testing and Adjusting....................................................................................................................................... 634 Sketch of Tools for Testing and Adjusting............................................................................................................................. 645 Engine and Cooling System................................................................................................................................................. 646 Examine Engine Speed.................................................................................................................................................. 646 How to Examine Engine Speed....................................................................................................................................... 646 Examine Boost Pressure................................................................................................................................................ 653 How to Examine Boost Pressure on Machine Monitor.................................................................................................................. 653 How to Examine Boost Pressure by Testing Tool..................................................................................................................... 654 Examine Exhaust Gas Temperature....................................................................................................................................... 657 How to Examine Exhaust Gas Temperature............................................................................................................................ 657 Examine Exhaust Gas Color............................................................................................................................................. 659 How to Examine Exhaust Gas Color with the Handy Smoke Checker..................................................................................................... 659 How to Examine Exhaust Gas Color with Smoke Meter................................................................................................................. 660 Examine Mass Air Flow and Temperature Sensor.......................................................................................................................... 662 How to Examine Mass Air Flow and Temperature Sensor............................................................................................................... 662 Examine and Adjust Valve Clearance.................................................................................................................................... 664 How to Examine Valve Clearance.................................................................................................................................... 664 How to Adjust Valve Clearance..................................................................................................................................... 665 Examine Compression Pressure.......................................................................................................................................... 666 How to Examine Compression Pressure............................................................................................................................... 666 Examine Blowby Pressure............................................................................................................................................... 669 How to Examine Blowby Pressure.................................................................................................................................... 669 Examine Engine Oil Pressure........................................................................................................................................... 672 How to Examine Engine Oil Pressure on Machine Monitor............................................................................................................. 672 How to Examine Engine Oil Pressure by Testing Tool................................................................................................................ 672 Examine EGR Valve and VGT Oil Pressure................................................................................................................................ 674 How to Examine EGR Valve and VGT Oil Pressure..................................................................................................................... 674 Examine Fuel Pressure................................................................................................................................................. 676 How to Examine Fuel Pressure...................................................................................................................................... 676 Examine Fuel Return Rate and Leakage.................................................................................................................................. 678 How to Examine Fuel Return Rate and Leakage....................................................................................................................... 679 Bleed Air from Fuel System............................................................................................................................................ 682 How to Bleed Air from Fuel System................................................................................................................................. 683 Examine Fuel Circuit for Leakage...................................................................................................................................... 684 How to Examine Fuel System for Leakage............................................................................................................................ 684 Handle Cylinder Cut-out Mode Operation................................................................................................................................ 686 Handle No-Injection Cranking Operation................................................................................................................................ 687 Examine KDPF, SCR and Muffler Stack for Looseness and Damage.......................................................................................................... 688 How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage............................................................................................... 688 Examine Installed Condition of Cylinder Heads and Manifolds........................................................................................................... 689 How to Examine Installed Condition of Cylinder Heads and Manifolds................................................................................................ 689 Examine Engine Piping for Damage and Looseness........................................................................................................................ 690 How to Examine Engine Piping for Damage and Looseness............................................................................................................. 690 Clean Fuel Doser...................................................................................................................................................... 691 How to Clean Fuel Doser........................................................................................................................................... 691 Write Injector Compensation Value to Engine Controller................................................................................................................ 694 How to Write Injector Compensation Value.......................................................................................................................... 694 Write Correction for Ash in Soot Accumulation to Engine Controller.................................................................................................... 701 How to Write Correction for Ash in Soot Accumulation to Engine Controller......................................................................................... 701 Examine SCR Related Functions......................................................................................................................................... 702 Examine DEF Pump Raised Pressure.................................................................................................................................. 706 Examine Injection Volume from DEF Injector........................................................................................................................ 709 Examine DEF Line Heater Relay 1................................................................................................................................... 714 Examine DEF Line Heater Relay 2................................................................................................................................... 718 Examine DEF Pump Heater Relay..................................................................................................................................... 722 Examine DEF Tank Heater Valve..................................................................................................................................... 726 Examine SCR Denitration Efficiency................................................................................................................................ 730 Clean DEF Tank........................................................................................................................................................ 734 How to Clean DEF Tank............................................................................................................................................. 734 Clean DEF Pump........................................................................................................................................................ 738 How to Clean DEF Pump............................................................................................................................................. 738 Power Train............................................................................................................................................................... 744 Examine and Adjust Power Train Oil Pressure........................................................................................................................... 744 How to Examine Power Train Oil Pressure........................................................................................................................... 746 How to Adjust Power Train Oil Pressure............................................................................................................................ 761 Adjust Transmission Input Shaft Speed Sensor.......................................................................................................................... 762 How to Adjust Transmission Input Shaft Speed Sensor............................................................................................................... 762 Adjust Transmission Output Shaft Speed Sensor......................................................................................................................... 764 How to Adjust Transmission Output Shaft Speed Sensor.............................................................................................................. 764 Flush Torque Converter and Transmission Hydraulic Circuit............................................................................................................. 766 How to Flush Torque Converter and Transmission Hydraulic Circuit.................................................................................................. 766 Move Disabled Machine Due to Transmission Valve Failure............................................................................................................... 768 How to Move Disabled Machine Due to Transmission Valve Failure.................................................................................................... 768 Examine Drive Shaft for Looseness, Backlash, and Damage............................................................................................................... 770 How to Examine Drive Shaft for Looseness, Backlash, and Damage.................................................................................................... 770 Steering System........................................................................................................................................................... 771 Examine Steering Wheel................................................................................................................................................ 771 How to Examine Steering Wheel..................................................................................................................................... 771 Examine and Adjust Steering Circuit Oil Pressure...................................................................................................................... 773 How to Examine Steering Circuit Oil Pressure...................................................................................................................... 773 How to Adjust Steering Circuit Oil Pressure....................................................................................................................... 778 Bleed Air from Steering Cylinder Circuit.............................................................................................................................. 779 How to Bleed Air from Steering Cylinder Circuit................................................................................................................... 779 Examine and Adjust Steering Stop Valve................................................................................................................................ 780 How to Examine Steering Stop Valve................................................................................................................................ 780 How to Adjust Steering Stop Valve................................................................................................................................. 780 Brake System.............................................................................................................................................................. 782 Release Remained Pressure in Brake Accumulator Circuit................................................................................................................ 782 How to Release Remained Pressure in Brake Accumulator Circuit..................................................................................................... 782 Examine Wheel Brake Oil Pressure...................................................................................................................................... 783 How to Examine Wheel Brake Oil Pressure........................................................................................................................... 783 Examine and Adjust Brake Accumulator Charge Pressure.................................................................................................................. 785 How to Examine Brake Accumulator Charge Pressure.................................................................................................................. 785 How to Adjust Brake Accumulator Charge Pressure................................................................................................................... 786 Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas..................................................................................................... 787 How to Examine Accumulator Nitrogen Gas Pressure for Brake........................................................................................................ 787 How to Charge Accumulator Nitrogen Gas for Brake.................................................................................................................. 790 How to Release Nitrogen Gas When You Discard Accumulator.......................................................................................................... 794 Bleed Air from Brake Circuit.......................................................................................................................................... 796 How to Bleed Air from Brake Circuit............................................................................................................................... 796 Examine Brake Performance............................................................................................................................................. 799 How to Examine Brake Performance.................................................................................................................................. 799 Examine Brake Pedal................................................................................................................................................... 800 How to Examine Brake Pedal........................................................................................................................................ 800 Examine and Adjust Brake Pedal and Linkage............................................................................................................................ 801 How to Examine Brake Pedal and Linkage............................................................................................................................ 801 How to Adjust Brake Pedal and Linkage............................................................................................................................. 801 Adjust Left Brake Pedal Operation Switch.............................................................................................................................. 802 How to Adjust Left Brake Pedal Operation Switch................................................................................................................... 802 Examine Pressure Decrease of Wheel Brake.............................................................................................................................. 803 How to Examine Pressure Decrease of Wheel Brake................................................................................................................... 804 Examine Wear of Wheel Brake Disc...................................................................................................................................... 806 How to Examine Wear of Wheel Brake Disc........................................................................................................................... 806 Examine Parking Brake Oil Pressure.................................................................................................................................... 808 How to Examine Parking Brake Oil Pressure......................................................................................................................... 808 Examine Parking Brake Performance..................................................................................................................................... 810 How to Examine Parking Brake Performance.......................................................................................................................... 810 Release Parking Brake Manually........................................................................................................................................ 811 How to Release Parking Brake with Parking Brake Emergency Release Valve........................................................................................... 811 How to Release Parking Brake with Bolt............................................................................................................................ 812 Examine Wear Volume of Parking Brake Disc............................................................................................................................. 814 How to Examine Wear Quantity of Parking Brake Disc................................................................................................................ 814 Hydraulic System.......................................................................................................................................................... 816 Release Remained Pressure from Work Equipment Circuit................................................................................................................. 816 How to Release Remained Pressure from Work Equipment Circuit...................................................................................................... 816 Examine and Adjust Work Equipment Oil Pressure........................................................................................................................ 818 How to Examine Work Equipment Oil Pressure........................................................................................................................ 818 How to Adjust Work Equipment Oil Pressure......................................................................................................................... 823 Examine and Adjust Work Equipment EPC Oil Pressure.................................................................................................................... 824 How to Examine Work Equipment EPC Oil Pressure.................................................................................................................... 824 How to Adjust Work Equipment EPC Oil Pressure..................................................................................................................... 826 Bleed Air from Work Equipment Circuit................................................................................................................................. 827 How to Bleed Air from Work Equipment Circuit...................................................................................................................... 827 Examine Cooling Fan Speed............................................................................................................................................. 829 How to Examine Cooling Fan Speed.................................................................................................................................. 829 Examine Cooling Fan Circuit Oil Pressure.............................................................................................................................. 830 How to Examine Cooling Fan Circuit Oil Pressure................................................................................................................... 830 Bleed Air from Cooling Fan Circuit.................................................................................................................................... 834 How to Bleed Air from Cooling Fan Circuit......................................................................................................................... 834 Examine ECSS Accumulator Nitrogen Gas Pressure and Charge Accumulator with Nitrogen Gas............................................................................... 836 How to Examine ECSS Accumulator Nitrogen Gas Pressure............................................................................................................. 837 How to Charge ECSS Accumulator with Nitrogen Gas.................................................................................................................. 842 Work Equipment............................................................................................................................................................ 850 Examine and Adjust Bucket Potentiometer Lever......................................................................................................................... 850 How to Examine Bucket Potentiometer Lever......................................................................................................................... 850 How to Adjust Bucket Potentiometer Lever.......................................................................................................................... 850 Examine and Adjust Boom Potentiometer Lever........................................................................................................................... 852 How to Examine Boom Potentiometer Lever........................................................................................................................... 852 How to Adjust Boom Potentiometer Lever............................................................................................................................ 852 CAB Related Parts......................................................................................................................................................... 853 Examine Directional Lever............................................................................................................................................. 853 How to Examine Directional Lever.................................................................................................................................. 853 Examine Work Equipment Control Lever.................................................................................................................................. 854 How to Examine Work Equipment Control Lever....................................................................................................................... 854 Examine Multifunction Mono-Lever...................................................................................................................................... 855 How to Examine Multifunction Mono-Lever........................................................................................................................... 855 Examine AJSS Lever (For AJSS Spec).................................................................................................................................... 857 How to Examine AJSS Lever......................................................................................................................................... 857 Examine Steering Lock Lever (AJSS Specification)...................................................................................................................... 860 How to Examine Steering Lock Lever................................................................................................................................ 860 Examine and Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor (AJSS Specifications).......................................................................... 861 How to Examine AJSS Lever Angle Sensor and AJSS Frame Angle Sensor................................................................................................ 861 How to Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor................................................................................................. 861 Examine and Adjust Steering Stopper Bolt (For AJSS Spec).............................................................................................................. 863 How to Examine Steering Stopper Bolt.............................................................................................................................. 863 How to Adjust Steering Stopper Bolt............................................................................................................................... 863 Adjust Play of Operator Seat.......................................................................................................................................... 865 How to Adjust Play of Operator Seat............................................................................................................................... 865 Electrical System......................................................................................................................................................... 866 Set and Adjust Each Equipment......................................................................................................................................... 866 Set and Operate Machine Monitor....................................................................................................................................... 871 Operator Mode..................................................................................................................................................... 875 Function to Show Technician Identification Status Screen.......................................................................................................... 875 Function to Show Operator Identification Input Screen............................................................................................................. 875 Examine Function by LCD (Liquid Crystal Display).................................................................................................................. 876 Examine Function of Service Meter and Odometer.................................................................................................................... 877 How to Set Usage Limitation and Change Maintenance Password....................................................................................................... 877 Service Mode...................................................................................................................................................... 881 How to Operate Service Mode....................................................................................................................................... 881 How to See Pre-defined Monitoring Information..................................................................................................................... 884 How to Examine Self-Define Monitor Information.................................................................................................................... 897 Abnormality Record Menu........................................................................................................................................... 913 How to See Maintenance Record..................................................................................................................................... 918 Maintenance Mode Setting.......................................................................................................................................... 920 How to Set Phone Number Entry..................................................................................................................................... 925 Default Menu...................................................................................................................................................... 927 Diagnostic Tests Menu............................................................................................................................................. 943 Adjustment Menu................................................................................................................................................... 954 No-Injection Cranking Operation...................................................................................................................................1000 KOMTRAX Settings Menu.............................................................................................................................................1003 How to Show Service Message.......................................................................................................................................1008 How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal)......................................................................................................1010 How to Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal)...................................................................................................1014 How to Start Up KOMTRAX System (Machine with Gateway Function Controller).............................................................................................1016 How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller)..........................................................................................1022 Adjust Rearview Camera Angle..........................................................................................................................................1024 How to Adjust Rearview Camera Angle...............................................................................................................................1024 Set Region of Bluetooth(R) Compatible Radio...........................................................................................................................1025 How to Set Region of Bluetooth(R) Compatible Radio................................................................................................................1025 Handle Voltage Circuit of Engine Controller...........................................................................................................................1027 Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal)......................................................................................................1028 Handle Battery Disconnect Switch (Machine with Gateway Function Controller)...........................................................................................1029 Examine Diodes........................................................................................................................................................1030 How to Examine Diodes by Digital Tester...........................................................................................................................1030 How to Examine Diodes by Analog Tester............................................................................................................................1030 Auto-Greasing Device......................................................................................................................................................1031 Bleed the Air in Auto-Greasing System.................................................................................................................................1031 How to Bleed the Air in Auto-Greasing System......................................................................................................................1031 Change Lubrication Time and Lubrication Interval......................................................................................................................1034 How to Change Lubrication Time and Lubrication Interval...........................................................................................................1035 Examine and Fill Auto-Greasing........................................................................................................................................1037 How to Examine Auto-Greasing......................................................................................................................................1037 How to Fill Auto-Greasing.........................................................................................................................................1038 Pm Clinic.................................................................................................................................................................1039 Pm Clinic Service.....................................................................................................................................................1039 Pm Clinic Check Sheet: WA500-8E0..................................................................................................................................1042 40 Troubleshooting............................................................................................................................................................1053 Table of Contents.........................................................................................................................................................1054 Precautions Before Work...................................................................................................................................................1069 Abbreviation List.........................................................................................................................................................1070 Related Information to Troubleshooting....................................................................................................................................1076 General Troubleshooting Points........................................................................................................................................1076 Troubleshooting Points for Urea SCR System............................................................................................................................1077 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)............................................................................................................................1100 Examine Air Cleaner Clogging......................................................................................................................................1101 Clean Outer Element...............................................................................................................................................1101 Replace Inner Element.............................................................................................................................................1104 Examine Hydraulic Oil Level.......................................................................................................................................1106 Examine Hydraulic Oil Strainer....................................................................................................................................1106 Examine Hydraulic Oil Filter......................................................................................................................................1109 Examine Oil Level in Transmission Case............................................................................................................................1112 Examine Oil Level in Front Axle Case..............................................................................................................................1114 Examine Oil Level in Rear Axle Case...............................................................................................................................1114 Bleed Air from Fuel System........................................................................................................................................1115 Bleed Air from Hydraulic System...................................................................................................................................1115 How to Examine Electric Equipment.................................................................................................................................1115 Preparation for Troubleshooting of Electrical System..................................................................................................................1121 Procedure for Troubleshooting.........................................................................................................................................1134 Symptom and Troubleshooting Numbers...................................................................................................................................1136 Information Shown in Troubleshooting Table............................................................................................................................1141 Connector List and Layout (Machine with KOMTRAX Terminal).............................................................................................................1143 Connector List and Layout (Machine with Gateway Function Controller)..................................................................................................1171 Connector Contact Connection Table....................................................................................................................................1199 T-Branch Box and T-Branch Adapter Table...............................................................................................................................1239 Fuse Location Table (Machine with KOMTRAX Terminal)...................................................................................................................1245 Fuse Location Table (Machine with Gateway Function Controller)........................................................................................................1249 Precautions When You Clean and Replace KDPF (KCSF and KDOC)...........................................................................................................1253 Prepare Troubleshoot Machine Monitor..................................................................................................................................1257 Procedure to Make Harness Checker on Machine Monitor LCD Unit.........................................................................................................1259 Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])..................................................................................1265 Failure Code Table....................................................................................................................................................1267 Troubleshooting by Failure Code (Display of Code).........................................................................................................................1292 Failure Code [1500L0].................................................................................................................................................1292 Failure Code [15B0NX].................................................................................................................................................1293 Failure Code [15SAL1].................................................................................................................................................1295 Failure Code [15SALH].................................................................................................................................................1297 Failure Code [15SBL1].................................................................................................................................................1299 Failure Code [15SBLH].................................................................................................................................................1301 Failure Code [15SEL1].................................................................................................................................................1303 Failure Code [15SELH].................................................................................................................................................1305 Failure Code [15SFL1].................................................................................................................................................1307 Failure Code [15SFLH].................................................................................................................................................1309 Failure Code [15SGL1].................................................................................................................................................1311 Failure Code [15SGLH].................................................................................................................................................1313 Failure Code [15SHL1].................................................................................................................................................1315 Failure Code [15SHLH].................................................................................................................................................1317 Failure Code [2F00MA].................................................................................................................................................1320 Failure Code [2F00MB].................................................................................................................................................1324 Failure Code [2G42ZG].................................................................................................................................................1327 Failure Code [2G43ZG].................................................................................................................................................1329 Failure Code [879AKA].................................................................................................................................................1331 Failure Code [879AKB].................................................................................................................................................1333 Failure Code [879BKA].................................................................................................................................................1335 Failure Code [879BKB].................................................................................................................................................1337 Failure Code [879CKA].................................................................................................................................................1339 Failure Code [879CKB].................................................................................................................................................1341 Failure Code [879DKZ].................................................................................................................................................1343 Failure Code [879EMC].................................................................................................................................................1345 Failure Code [879FMC].................................................................................................................................................1348 Failure Code [989A00].................................................................................................................................................1351 Failure Code [989L00].................................................................................................................................................1352 Failure Code [989M00].................................................................................................................................................1353 Failure Code [989N00].................................................................................................................................................1354 Failure Code [A1U0N3].................................................................................................................................................1355 Failure Code [A1U0N4].................................................................................................................................................1357 Failure Code [AA10NX].................................................................................................................................................1359 Failure Code [AB00KE].................................................................................................................................................1361 Failure Code [AB00KY].................................................................................................................................................1363 Failure Code [AQ10N3].................................................................................................................................................1365 Failure Code [AS00N3].................................................................................................................................................1367 Failure Code [AS00R2].................................................................................................................................................1369 Failure Code [AS00R3].................................................................................................................................................1370 Failure Code [AS00R4].................................................................................................................................................1371 Failure Code [AS00R5].................................................................................................................................................1372 Failure Code [AS00R6].................................................................................................................................................1373 Failure Code [AS00ZK].................................................................................................................................................1374 Failure Code [AS10KM].................................................................................................................................................1375 Failure Code [AS10NR].................................................................................................................................................1376 Failure Code [AS10NT].................................................................................................................................................1377 Failure Code [B@BAZG].................................................................................................................................................1378 Failure Code [B@BCNS].................................................................................................................................................1379 Failure Code [B@BCQA].................................................................................................................................................1380 Failure Code [B@BCZK].................................................................................................................................................1382 Failure Code [B@CENS].................................................................................................................................................1384 Failure Code [B@HANS].................................................................................................................................................1385 Failure Code [CA115]..................................................................................................................................................1386 Failure Code [CA122]..................................................................................................................................................1390 Failure Code [CA123]..................................................................................................................................................1392 Failure Code [CA131]..................................................................................................................................................1394 Failure Code [CA132]..................................................................................................................................................1396 Failure Code [CA135]..................................................................................................................................................1398 Failure Code [CA141]..................................................................................................................................................1400 Failure Code [CA144]..................................................................................................................................................1402 Failure Code [CA145]..................................................................................................................................................1404 Failure Code [CA153]..................................................................................................................................................1406 Failure Code [CA154]..................................................................................................................................................1409 Failure Code [CA187]..................................................................................................................................................1411 Failure Code [CA221]..................................................................................................................................................1413 Failure Code [CA222]..................................................................................................................................................1415 Failure Code [CA227]..................................................................................................................................................1417 Failure Code [CA234]..................................................................................................................................................1419 Failure Code [CA238]..................................................................................................................................................1420 Failure Code [CA239]..................................................................................................................................................1421 Failure Code [CA249]..................................................................................................................................................1422 Failure Code [CA256]..................................................................................................................................................1424 Failure Code [CA271]..................................................................................................................................................1426 Failure Code [CA272]..................................................................................................................................................1428 Failure Code [CA273]..................................................................................................................................................1429 Failure Code [CA274]..................................................................................................................................................1431 Failure Code [CA322]..................................................................................................................................................1432 Failure Code [CA323]..................................................................................................................................................1434 Failure Code [CA324]..................................................................................................................................................1436 Failure Code [CA325]..................................................................................................................................................1438 Failure Code [CA331]..................................................................................................................................................1440 Failure Code [CA332]..................................................................................................................................................1442 Failure Code [CA343]..................................................................................................................................................1444 Failure Code [CA351]..................................................................................................................................................1446 Failure Code [CA352]..................................................................................................................................................1448 Failure Code [CA356]..................................................................................................................................................1450 Failure Code [CA357]..................................................................................................................................................1452 Failure Code [CA386]..................................................................................................................................................1454 Failure Code [CA431]..................................................................................................................................................1456 Failure Code [CA432]..................................................................................................................................................1459 Failure Code [CA441]..................................................................................................................................................1463 Failure Code [CA442]..................................................................................................................................................1465 Failure Code [CA449]..................................................................................................................................................1467 Failure Code [CA451]..................................................................................................................................................1468 Failure Code [CA452]..................................................................................................................................................1470 Failure Code [CA515]..................................................................................................................................................1472 Failure Code [CA516]..................................................................................................................................................1474 Failure Code [CA553]..................................................................................................................................................1476 Failure Code [CA555]..................................................................................................................................................1477 Failure Code [CA556]..................................................................................................................................................1479 Failure Code [CA559]..................................................................................................................................................1481 Failure Code [CA595]..................................................................................................................................................1486 Failure Code [CA687]..................................................................................................................................................1488 Failure Code [CA689]..................................................................................................................................................1490 Failure Code [CA691]..................................................................................................................................................1492 Failure Code [CA692]..................................................................................................................................................1494 Failure Code [CA697]..................................................................................................................................................1496 Failure Code [CA698]..................................................................................................................................................1497 Failure Code [CA731]..................................................................................................................................................1498 Failure Code [CA778]..................................................................................................................................................1502 Failure Code [CA1117].................................................................................................................................................1504 Failure Code [CA1664].................................................................................................................................................1506 Failure Code [CA1669].................................................................................................................................................1509 Failure Code [CA1673].................................................................................................................................................1510 Failure Code [CA1677].................................................................................................................................................1511 Failure Code [CA1678].................................................................................................................................................1512 Failure Code [CA1682].................................................................................................................................................1513 Failure Code [CA1683].................................................................................................................................................1517 Failure Code [CA1684].................................................................................................................................................1519 Failure Code [CA1686].................................................................................................................................................1521 Failure Code [CA1691].................................................................................................................................................1522 Failure Code [CA1694].................................................................................................................................................1524 Failure Code [CA1695].................................................................................................................................................1526 Failure Code [CA1696].................................................................................................................................................1528 Failure Code [CA1712].................................................................................................................................................1530 Failure Code [CA1713].................................................................................................................................................1533 Failure Code [CA1714].................................................................................................................................................1535 Failure Code [CA1715].................................................................................................................................................1536 Failure Code [CA1776].................................................................................................................................................1537 Failure Code [CA1777].................................................................................................................................................1540 Failure Code [CA1843].................................................................................................................................................1543 Failure Code [CA1844].................................................................................................................................................1545 Failure Code [CA1879].................................................................................................................................................1547 Failure Code [CA1881].................................................................................................................................................1549 Failure Code [CA1883].................................................................................................................................................1551 Failure Code [CA1885].................................................................................................................................................1554 Failure Code [CA1887].................................................................................................................................................1556 Failure Code [CA1921].................................................................................................................................................1558 Failure Code [CA1922].................................................................................................................................................1561 Failure Code [CA1923].................................................................................................................................................1566 Failure Code [CA1924].................................................................................................................................................1568 Failure Code [CA1925].................................................................................................................................................1570 Failure Code [CA1927].................................................................................................................................................1572 Failure Code [CA1928].................................................................................................................................................1574 Failure Code [CA1942].................................................................................................................................................1576 Failure Code [CA1963].................................................................................................................................................1578 Failure Code [CA1977].................................................................................................................................................1582 Failure Code [CA1993].................................................................................................................................................1584 Failure Code [CA2185].................................................................................................................................................1587 Failure Code [CA2186].................................................................................................................................................1589 Failure Code [CA2249].................................................................................................................................................1591 Failure Code [CA2265].................................................................................................................................................1596 Failure Code [CA2266].................................................................................................................................................1598 Failure Code [CA2271].................................................................................................................................................1600 Failure Code [CA2272].................................................................................................................................................1602 Failure Code [CA2349].................................................................................................................................................1604 Failure Code [CA2353].................................................................................................................................................1606 Failure Code [CA2357].................................................................................................................................................1608 Failure Code [CA2381].................................................................................................................................................1610 Failure Code [CA2382].................................................................................................................................................1612 Failure Code [CA2383].................................................................................................................................................1614 Failure Code [CA2386].................................................................................................................................................1616 Failure Code [CA2387].................................................................................................................................................1618 Troubleshooting Flowchart.........................................................................................................................................1622 Failure Code [CA2555].................................................................................................................................................1623 Failure Code [CA2556].................................................................................................................................................1625 Failure Code [CA2637].................................................................................................................................................1627 Failure Code [CA2639].................................................................................................................................................1629 Failure Code [CA2732].................................................................................................................................................1631 Failure Code [CA2733].................................................................................................................................................1633 Failure Code [CA2741].................................................................................................................................................1635 Failure Code [CA2765].................................................................................................................................................1636 Failure Code [CA2771].................................................................................................................................................1637 Failure Code [CA2777].................................................................................................................................................1643 Failure Code [CA2878].................................................................................................................................................1646 Failure Code [CA2881].................................................................................................................................................1649 Failure Code [CA2976].................................................................................................................................................1652 Failure Code [CA3133].................................................................................................................................................1654 Failure Code [CA3134].................................................................................................................................................1656 Failure Code [CA3135].................................................................................................................................................1658 Failure Code [CA3142].................................................................................................................................................1661 Failure Code [CA3143].................................................................................................................................................1662 Failure Code [CA3144].................................................................................................................................................1663 Failure Code [CA3146].................................................................................................................................................1666 Failure Code [CA3147].................................................................................................................................................1667 Failure Code [CA3148].................................................................................................................................................1668 Failure Code [CA3151].................................................................................................................................................1671 Failure Code [CA3165].................................................................................................................................................1676 Failure Code [CA3167].................................................................................................................................................1679 Failure Code [CA3229].................................................................................................................................................1683 Failure Code [CA3231].................................................................................................................................................1686 Failure Code [CA3232].................................................................................................................................................1689 Failure Code [CA3235].................................................................................................................................................1694 Failure Code [CA3239].................................................................................................................................................1696 Failure Code [CA3241].................................................................................................................................................1699 Failure Code [CA3242].................................................................................................................................................1702 Failure Code [CA3251].................................................................................................................................................1705 Failure Code [CA3253].................................................................................................................................................1708 Failure Code [CA3254].................................................................................................................................................1713 Failure Code [CA3255].................................................................................................................................................1717 Failure Code [CA3256].................................................................................................................................................1720 Failure Code [CA3311].................................................................................................................................................1723 Failure Code [CA3312].................................................................................................................................................1726 Failure Code [CA3313].................................................................................................................................................1729 Failure Code [CA3314].................................................................................................................................................1730 Failure Code [CA3315].................................................................................................................................................1731 Failure Code [CA3316].................................................................................................................................................1735 Failure Code [CA3317].................................................................................................................................................1736 Failure Code [CA3318].................................................................................................................................................1737 Failure Code [CA3319].................................................................................................................................................1741 Failure Code [CA3321].................................................................................................................................................1742 Failure Code [CA3322].................................................................................................................................................1743 Failure Code [CA3419].................................................................................................................................................1747 Failure Code [CA3421].................................................................................................................................................1749 Failure Code [CA3497].................................................................................................................................................1751 Failure Code [CA3498].................................................................................................................................................1752 Failure Code [CA3543].................................................................................................................................................1753 Failure Code [CA3545].................................................................................................................................................1758 Failure Code [CA3547].................................................................................................................................................1760 Failure Code [CA3558].................................................................................................................................................1761 Failure Code [CA3559].................................................................................................................................................1763 Failure Code [CA3562].................................................................................................................................................1765 Failure Code [CA3563].................................................................................................................................................1767 Failure Code [CA3567].................................................................................................................................................1770 Failure Code [CA3568].................................................................................................................................................1773 Failure Code [CA3571].................................................................................................................................................1779 Failure Code [CA3572].................................................................................................................................................1781 Failure Code [CA3574].................................................................................................................................................1783 Failure Code [CA3575].................................................................................................................................................1786 Failure Code [CA3577].................................................................................................................................................1788 Failure Code [CA3578].................................................................................................................................................1790 Failure Code [CA3582].................................................................................................................................................1792 Failure Code [CA3583].................................................................................................................................................1799 Failure Code [CA3596].................................................................................................................................................1801 Failure Code [CA3649].................................................................................................................................................1804 Failure Code [CA3681].................................................................................................................................................1807 Failure Code [CA3682].................................................................................................................................................1812 Failure Code [CA3713].................................................................................................................................................1818 Failure Code [CA3717].................................................................................................................................................1821 Failure Code [CA3718].................................................................................................................................................1822 Failure Code [CA3725].................................................................................................................................................1823 Failure Code [CA3748].................................................................................................................................................1826 Failure Code [CA3751].................................................................................................................................................1829 Failure Code [CA3755].................................................................................................................................................1831 Failure Code [CA3866].................................................................................................................................................1833 Failure Code [CA3867].................................................................................................................................................1837 Failure Code [CA3868].................................................................................................................................................1840 Failure Code [CA3899].................................................................................................................................................1844 Failure Code [CA3911].................................................................................................................................................1846 Failure Code [CA3912].................................................................................................................................................1850 Failure Code [CA3932].................................................................................................................................................1852 Failure Code [CA3933].................................................................................................................................................1854 Failure Code [CA3934].................................................................................................................................................1856 Failure Code [CA3935].................................................................................................................................................1859 Failure Code [CA3936].................................................................................................................................................1861 Failure Code [CA4151].................................................................................................................................................1863 Failure Code [CA4152].................................................................................................................................................1867 Failure Code [CA4155].................................................................................................................................................1871 Failure Code [CA4156].................................................................................................................................................1873 Failure Code [CA4157].................................................................................................................................................1876 Failure Code [CA4158].................................................................................................................................................1878 Failure Code [CA4159].................................................................................................................................................1879 Failure Code [CA4161].................................................................................................................................................1880 Failure Code [CA4162].................................................................................................................................................1883 Failure Code [CA4163].................................................................................................................................................1886 Failure Code [CA4164].................................................................................................................................................1888 Failure Code [CA4165].................................................................................................................................................1891 Failure Code [CA4166].................................................................................................................................................1894 Failure Code [CA4168].................................................................................................................................................1896 Failure Code [CA4169].................................................................................................................................................1901 Failure Code [CA4171].................................................................................................................................................1906 Failure Code [CA4249].................................................................................................................................................1911 Failure Code [CA4251].................................................................................................................................................1915 Failure Code [CA4259].................................................................................................................................................1919 Failure Code [CA4261].................................................................................................................................................1923 Failure Code [CA4277].................................................................................................................................................1926 Failure Code [CA4281].................................................................................................................................................1929 Failure Code [CA4459].................................................................................................................................................1933 Failure Code [CA4461].................................................................................................................................................1935 Failure Code [CA4658].................................................................................................................................................1938 Failure Code [CA4731].................................................................................................................................................1942 Failure Code [CA4732].................................................................................................................................................1943 Failure Code [CA4739].................................................................................................................................................1944 Failure Code [CA4768].................................................................................................................................................1945 Failure Code [CA4769].................................................................................................................................................1947 Failure Code [CA4842].................................................................................................................................................1950 Failure Code [CA4952] (Machine with KOMTRAX Terminal).................................................................................................................1953 Failure Code [CA4952] (Machine with Gateway Function Controller)......................................................................................................1955 Failure Code [CA5115].................................................................................................................................................1957 Failure Code [CA5179].................................................................................................................................................1960 Failure Code [CA5181].................................................................................................................................................1962 Failure Code [CA5383].................................................................................................................................................1964 Failure Code [D160KA].................................................................................................................................................1966 Failure Code [D160KB].................................................................................................................................................1968 Failure Code [D160KY].................................................................................................................................................1970 Failure Code [D191KA].................................................................................................................................................1972 Failure Code [D191KB].................................................................................................................................................1975 Failure Code [D191KY].................................................................................................................................................1978 Failure Code [D192KA].................................................................................................................................................1980 Failure Code [D192KB].................................................................................................................................................1982 Failure Code [D192KY].................................................................................................................................................1984 Failure Code [D193KA].................................................................................................................................................1985 Failure Code [D193KB].................................................................................................................................................1987 Failure Code [D193KY].................................................................................................................................................1989 Failure Code [D193MC] (Applicable Machine: 90001 to 90960)............................................................................................................1991 Failure Code [D193MC] (Applicable Machine: 90961 and Up)..............................................................................................................1993 Failure Code [D19JKZ].................................................................................................................................................1995 Failure Code [D1E6KA].................................................................................................................................................1997 Failure Code [D1E6KB].................................................................................................................................................1999 Failure Code [D1E6KY].................................................................................................................................................2001 Failure Code [D5ZHKA].................................................................................................................................................2003 Failure Code [D5ZHKB].................................................................................................................................................2005 Failure Code [D5ZHKZ].................................................................................................................................................2007 Failure Code [D5ZHL6].................................................................................................................................................2010 Failure Code [D5ZMLD].................................................................................................................................................2012 Failure Code [D811MC] (Machine with KOMTRAX Terminal).................................................................................................................2014 Failure Code [D811MC] (Machine with Gateway Function Controller)......................................................................................................2015 Failure Code [D862KA] (Machine with KOMTRAX Terminal).................................................................................................................2016 Failure Code [D862KA] (Machine with Gateway Function Controller)......................................................................................................2017 Failure Code [D8ALKA] (Machine with KOMTRAX Terminal).................................................................................................................2018 Failure Code [D8ALKA] (Machine with Gateway Function Controller)......................................................................................................2020 Failure Code [D8ALKB] (Machine with KOMTRAX Terminal).................................................................................................................2022 Failure Code [D8ALKB] (Machine with Gateway Function Controller)......................................................................................................2024 Failure Code [D8AQK4] (Machine with KOMTRAX Terminal).................................................................................................................2026 Failure Code [D8AQK4] (Machine with Gateway Function Controller)......................................................................................................2027 Failure Code [D8AQKR] (Machine with KOMTRAX Terminal).................................................................................................................2028 Failure Code [D8AQKR] (Machine with Gateway Function Controller)......................................................................................................2030 Failure Code [D8G1KT].................................................................................................................................................2032 Failure Code [D8G6KT].................................................................................................................................................2033 Failure Code [DAF0KT].................................................................................................................................................2034 Failure Code [DAF0MB].................................................................................................................................................2035 Failure Code [DAF0MC].................................................................................................................................................2036 Failure Code [DAF3KK].................................................................................................................................................2037 Failure Code [DAF8KB].................................................................................................................................................2039 Failure Code [DAFDKB].................................................................................................................................................2041 Failure Code [DAFGMC] (Machine with KOMTRAX Terminal).................................................................................................................2043 Failure Code [DAFGMC] (Machine with Gateway Function Controller)......................................................................................................2044 Failure Code [DAFLKA] (Machine with KOMTRAX Terminal).................................................................................................................2045 Failure Code [DAFLKA] (Machine with Gateway Function Controller)......................................................................................................2047 Failure Code [DAFLKB] (Machine with KOMTRAX Terminal).................................................................................................................2049 Failure Code [DAFLKB] (Machine with Gateway Function Controller)......................................................................................................2051 Failure Code [DAFQKR] (Machine with KOMTRAX Terminal).................................................................................................................2053 Failure Code [DAFQKR] (Machine with Gateway Function Controller)......................................................................................................2054 Failure Code [DAQ0KK].................................................................................................................................................2055 Failure Code [DAQ0KT].................................................................................................................................................2058 Failure Code [DAQ0MC].................................................................................................................................................2059 Failure Code [DAQ1KA].................................................................................................................................................2060 Failure Code [DAQ2KK].................................................................................................................................................2063 Failure Code [DAQ2KT].................................................................................................................................................2066 Failure Code [DAQ4KB].................................................................................................................................................2069 Failure Code [DAQ9KQ].................................................................................................................................................2071 Failure Code [DAQLKA] (Machine with KOMTRAX Terminal).................................................................................................................2072 Failure Code [DAQLKA] (Machine with Gateway Function Controller)......................................................................................................2074 Failure Code [DAQLKB] (Machine with KOMTRAX Terminal).................................................................................................................2076 Failure Code [DAQLKB] (Machine with Gateway Function Controller)......................................................................................................2078 Failure Code [DAQQKR].................................................................................................................................................2080 Failure Code [DAQRKR].................................................................................................................................................2081 Failure Code [DAQRMA].................................................................................................................................................2082 Failure Code [DAZ9KQ].................................................................................................................................................2083 Failure Code [DAZQKR].................................................................................................................................................2084 Failure Code [DB2QKR] (Machine with KOMTRAX Terminal).................................................................................................................2085 Failure Code [DB2QKR] (Machine with Gateway Function Controller)......................................................................................................2090 Failure Code [DB2RKR].................................................................................................................................................2095 Failure Code [DB90KK].................................................................................................................................................2101 Failure Code [DB90KT].................................................................................................................................................2104 Failure Code [DB90MC].................................................................................................................................................2105 Failure Code [DB91KA].................................................................................................................................................2106 Failure Code [DB92KK] (Applicable Machine: 90001 to 90960)............................................................................................................2109 Failure Code [DB92KK] (Applicable Machine: 90961 and Up)..............................................................................................................2112 Failure Code [DB92KT].................................................................................................................................................2115 Failure Code [DB95KX] (Applicable Machine: 90001 to 90960)............................................................................................................2118 Failure Code [DB95KX] (Applicable Machine: 90961 and Up)..............................................................................................................2121 Failure Code [DB96KX] (Applicable Machine: 90001 to 90960)............................................................................................................2124 Failure Code [DB96KX] (Applicable Machine: 90961 and Up)..............................................................................................................2126 Failure Code [DB99KQ].................................................................................................................................................2128 Failure Code [DB9LKA] (Machine with KOMTRAX Terminal).................................................................................................................2129 Failure Code [DB9LKA] (Machine with Gateway Function Controller)......................................................................................................2131 Failure Code [DB9LKB] (Machine with KOMTRAX Terminal).................................................................................................................2133 Failure Code [DB9LKB] (Machine with Gateway Function Controller)......................................................................................................2135 Failure Code [DB9QKR].................................................................................................................................................2137 Failure Code [DB9RKR].................................................................................................................................................2138 Failure Code [DB9RMA].................................................................................................................................................2139 Failure Code [DBE5KX] (Applicable Machine: 90001 to 90960)............................................................................................................2140 Failure Code [DBE5KX] (Applicable Machine: 90961 and Up)..............................................................................................................2142 Failure Code [DBE6KX].................................................................................................................................................2144 Failure Code [DD1ALD].................................................................................................................................................2146 Failure Code [DDA8KY].................................................................................................................................................2148 Failure Code [DDA9KY].................................................................................................................................................2150 Failure Code [DDAAL6].................................................................................................................................................2152 Failure Code [DDAAL6].................................................................................................................................................2154 Failure Code [DDB6L4].................................................................................................................................................2157 Failure Code [DDD1LD].................................................................................................................................................2160 Failure Code [DDE5KA].................................................................................................................................................2162 Failure Code [DDK3KA].................................................................................................................................................2164 Failure Code [DDK3KB].................................................................................................................................................2167 Failure Code [DDK4KA].................................................................................................................................................2170 Failure Code [DDK4KB].................................................................................................................................................2173 Failure Code [DDK5L4].................................................................................................................................................2175 Failure Code [DDK6KA].................................................................................................................................................2177 Failure Code [DDK6KB].................................................................................................................................................2180 Failure Code [DDKLKA] (Applicable Machine: 90001 to 90960)............................................................................................................2183 Failure Code [DDKLKA] (Applicable Machine: 90961 and Up)..............................................................................................................2185 Failure Code [DDKLKB] (Applicable Machine: 90001 to 90960)............................................................................................................2188 Failure Code [DDKLKB] (Applicable Machine: 90961 and Up)..............................................................................................................2190 Failure Code [DDNRKA].................................................................................................................................................2192 Failure Code [DDNRKY] (Applicable Machine: 90001 to 90960)............................................................................................................2195 Failure Code [DDNRKY] (Applicable Machine: 90961 and Up)..............................................................................................................2197 Failure Code [DDP5KA].................................................................................................................................................2199 Failure Code [DDT0L4].................................................................................................................................................2201 Failure Code [DDT4LD].................................................................................................................................................2203 Failure Code [DDT9LD].................................................................................................................................................2205 Failure Code [DDTALD].................................................................................................................................................2207 Failure Code [DDW9LD].................................................................................................................................................2209 Failure Code [DDWLLD].................................................................................................................................................2211 Failure Code [DF10KA].................................................................................................................................................2213 Failure Code [DF10KB].................................................................................................................................................2216 Failure Code [DGF1KA].................................................................................................................................................2219 Failure Code [DGF1KB].................................................................................................................................................2221 Failure Code [DGH2KX].................................................................................................................................................2223 Failure Code [DGR2KB].................................................................................................................................................2225 Failure Code [DGR2KZ].................................................................................................................................................2227 Failure Code [DGT1KA].................................................................................................................................................2229 Failure Code [DGT1KB].................................................................................................................................................2231 Failure Code [DH21KA].................................................................................................................................................2233 Failure Code [DH21KB].................................................................................................................................................2236 Failure Code [DHA4KA].................................................................................................................................................2238 Failure Code [DHAAMA].................................................................................................................................................2240 Failure Code [DHACMA].................................................................................................................................................2242 Failure Code [DHPCKX].................................................................................................................................................2244 Failure Code [DHPDKX].................................................................................................................................................2247 Failure Code [DHQ2KX].................................................................................................................................................2250 Failure Code [DHT1KX].................................................................................................................................................2252 Failure Code [DHT2L6].................................................................................................................................................2255 Failure Code [DHT5KX].................................................................................................................................................2257 Failure Code [DHT7KX].................................................................................................................................................2260 Failure Code [DHT8KA].................................................................................................................................................2263 Failure Code [DHT8KB].................................................................................................................................................2266 Failure Code [DHT8ZG].................................................................................................................................................2268 Failure Code [DJF1KA].................................................................................................................................................2269 Failure Code [DK30KA].................................................................................................................................................2271 Failure Code [DK30KY].................................................................................................................................................2273 Failure Code [DK55KA].................................................................................................................................................2275 Failure Code [DK55KY].................................................................................................................................................2278 Failure Code [DK55L5].................................................................................................................................................2280 Failure Code [DK59KA] (Applicable Machine: 90001 to 90960)............................................................................................................2281 Failure Code [DK59KA] (Applicable Machine: 90961 and Up)..............................................................................................................2285 Failure Code [DK59KY] (Applicable Machine: 90001 to 90960)............................................................................................................2287 Failure Code [DK59KY] (Applicable Machine: 90961 and Up)..............................................................................................................2291 Failure Code [DK59L8] (Applicable Machine: 90001 to 90960)............................................................................................................2295 Failure Code [DK59L8] (Applicable Machine: 90961 and Up)..............................................................................................................2300 Failure Code [DK5AKA] (Applicable Machine: 90001 to 90960)............................................................................................................2305 Failure Code [DK5AKA] (Applicable Machine: 90961 and Up)..............................................................................................................2309 Failure Code [DK5AKY] (Applicable Machine: 90001 to 90960)............................................................................................................2313 Failure Code [DK5AKY] (Applicable Machine: 90961 and Up)..............................................................................................................2317 Failure Code [DK5BKA] (Applicable Machine: 90001 to 90960)............................................................................................................2321 Failure Code [DK5BKA] (Applicable Machine: 90961 and Up)..............................................................................................................2325 Failure Code [DK5BKY] (Applicable Machine: 90001 to 90960)............................................................................................................2329 Failure Code [DK5BKY] (Applicable Machine: 90961 and Up)..............................................................................................................2333 Failure Code [DK5BL8] (Applicable Machine: 90001 to 90960)............................................................................................................2337 Failure Code [DK5BL8] (Applicable Machine: 90961 and Up)..............................................................................................................2342 Failure Code [DK5CKA] (Applicable Machine: 90001 to 90960)............................................................................................................2347 Failure Code [DK5CKA] (Applicable Machine: 90961 and Up)..............................................................................................................2351 Failure Code [DK5CKY] (Applicable Machine: 90001 to 90960)............................................................................................................2355 Failure Code [DK5CKY] (Applicable Machine: 90961 and Up)..............................................................................................................2359 Failure Code [DK5DKA] (Applicable Machine: 90001 to 90960)............................................................................................................2363 Failure Code [DK5DKA] (Applicable Machine: 90961 and Up)..............................................................................................................2366 Failure Code [DK5DKY] (Applicable Machine: 90001 to 90960)............................................................................................................2369 Failure Code [DK5DKY] (Applicable Machine: 90961 and Up)..............................................................................................................2372 Failure Code [DK5DL8] (Applicable Machine: 90001 to 90960)............................................................................................................2375 Failure Code [DK5DL8] (Applicable Machine: 90961 and Up)..............................................................................................................2380 Failure Code [DK5EKA] (Applicable Machine: 90001 to 90960)............................................................................................................2385 Failure Code [DK5EKA] (Applicable Machine: 90961 and Up)..............................................................................................................2388 Failure Code [DK5EKY] (Applicable Machine: 90001 to 90960)............................................................................................................2391 Failure Code [DK5EKY] (Applicable Machine: 90961 and Up)..............................................................................................................2394 Failure Code [DK5FKA].................................................................................................................................................2397 Failure Code [DK5FKY].................................................................................................................................................2400 Failure Code [DK5FL8].................................................................................................................................................2403 Failure Code [DK5GKA].................................................................................................................................................2407 Failure Code [DK5GKY].................................................................................................................................................2410 Failure Code [DKA0KA].................................................................................................................................................2413 Failure Code [DKA0KY].................................................................................................................................................2416 Failure Code [DKA0L0].................................................................................................................................................2419 Failure Code [DKA1KA].................................................................................................................................................2422 Failure Code [DKA1KY].................................................................................................................................................2425 Failure Code [DKD0KA].................................................................................................................................................2428 Failure Code [DKD0KY].................................................................................................................................................2430 Failure Code [DKD0L8].................................................................................................................................................2432 Failure Code [DLF1KA].................................................................................................................................................2433 Failure Code [DLF1LC].................................................................................................................................................2435 Failure Code [DLM3KA].................................................................................................................................................2437 Failure Code [DLM3LC].................................................................................................................................................2439 Failure Code [DLT3KA].................................................................................................................................................2441 Failure Code [DLT3LC].................................................................................................................................................2443 Failure Code [DPQ1KR].................................................................................................................................................2445 Failure Code [DPQ2KR].................................................................................................................................................2448 Failure Code [DPQ3KR].................................................................................................................................................2451 Failure Code [DSJ0KR].................................................................................................................................................2455 Failure Code [DT20KB] (Applicable Machine: 90001 to 90960)............................................................................................................2459 Failure Code [DT20KB] (Applicable Machine: 90961 and Up)..............................................................................................................2461 Failure Code [DT22KB].................................................................................................................................................2463 Failure Code [DT23KB].................................................................................................................................................2465 Failure Code [DV00KB].................................................................................................................................................2467 Failure Code [DW2BKA].................................................................................................................................................2469 Failure Code [DW2BKB].................................................................................................................................................2470 Failure Code [DW2BKY].................................................................................................................................................2471 Failure Code [DW2BL1].................................................................................................................................................2472 Failure Code [DW2BLH].................................................................................................................................................2474 Failure Code [DW4PKA].................................................................................................................................................2476 Failure Code [DW4PKB].................................................................................................................................................2478 Failure Code [DW4PKY].................................................................................................................................................2480 Failure Code [DW4QKA].................................................................................................................................................2482 Failure Code [DW4QKB].................................................................................................................................................2484 Failure Code [DW4QKY].................................................................................................................................................2486 Failure Code [DW4RKA].................................................................................................................................................2488 Failure Code [DW4RKB].................................................................................................................................................2490 Failure Code [DW4RKY].................................................................................................................................................2492 Failure Code [DW4SKA].................................................................................................................................................2494 Failure Code [DW4SKB].................................................................................................................................................2496 Failure Code [DW4SKY].................................................................................................................................................2498 Failure Code [DW7BKA].................................................................................................................................................2500 Failure Code [DW7BKB].................................................................................................................................................2502 Failure Code [DW7BKY].................................................................................................................................................2504 Failure Code [DWM1KA] (Applicable Machine: 90001 to 90960)............................................................................................................2505 Failure Code [DWM1KA] (Applicable Machine: 90961 and Up)..............................................................................................................2507 Failure Code [DWM1KB] (Applicable Machine: 90001 to 90960)............................................................................................................2509 Failure Code [DWM1KB] (Applicable Machine: 90961 and Up)..............................................................................................................2511 Failure Code [DWM1KY].................................................................................................................................................2513 Failure Code [DWN6KA].................................................................................................................................................2515 Failure Code [DWN6KB].................................................................................................................................................2517 Failure Code [DWN6KY].................................................................................................................................................2519 Failure Code [DWN8KA].................................................................................................................................................2521 Failure Code [DWN8KB].................................................................................................................................................2523 Failure Code [DWN8KY].................................................................................................................................................2525 Failure Code [DX16KA].................................................................................................................................................2527 Failure Code [DX16KB].................................................................................................................................................2529 Failure Code [DX16KY].................................................................................................................................................2531 Failure Code [DXA1KA].................................................................................................................................................2533 Failure Code [DXA1KB].................................................................................................................................................2535 Failure Code [DXA1KY].................................................................................................................................................2537 Failure Code [DXF0KA].................................................................................................................................................2539 Failure Code [DXF0KB].................................................................................................................................................2541 Failure Code [DXF0KY].................................................................................................................................................2543 Failure Code [DXH1KA].................................................................................................................................................2545 Failure Code [DXH1KB].................................................................................................................................................2547 Failure Code [DXH1KY].................................................................................................................................................2549 Failure Code [DXH4KA].................................................................................................................................................2551 Failure Code [DXH4KB].................................................................................................................................................2553 Failure Code [DXH4KY].................................................................................................................................................2555 Failure Code [DXH5KA].................................................................................................................................................2557 Failure Code [DXH5KB].................................................................................................................................................2559 Failure Code [DXH5KY].................................................................................................................................................2561 Failure Code [DXH6KA].................................................................................................................................................2563 Failure Code [DXH6KB].................................................................................................................................................2565 Failure Code [DXH6KY].................................................................................................................................................2567 Failure Code [DXH7KA].................................................................................................................................................2569 Failure Code [DXH7KB].................................................................................................................................................2571 Failure Code [DXH7KY].................................................................................................................................................2573 Failure Code [DXH8KA].................................................................................................................................................2575 Failure Code [DXH8KB].................................................................................................................................................2577 Failure Code [DXH8KY].................................................................................................................................................2579 Failure Code [DXHHKA].................................................................................................................................................2581 Failure Code [DXHHKB].................................................................................................................................................2583 Failure Code [DXHHKY].................................................................................................................................................2585 Failure Code [DXHJKA].................................................................................................................................................2587 Failure Code [DXHJKB].................................................................................................................................................2589 Failure Code [DXHJKY].................................................................................................................................................2591 Failure Code [DXHKKA].................................................................................................................................................2593 Failure Code [DXHKKB].................................................................................................................................................2595 Failure Code [DXHKKY].................................................................................................................................................2597 Failure Code [DXHLKA].................................................................................................................................................2599 Failure Code [DXHLKB].................................................................................................................................................2601 Failure Code [DXHLKY].................................................................................................................................................2603 Failure Code [DXHMKA].................................................................................................................................................2605 Failure Code [DXHMKB].................................................................................................................................................2607 Failure Code [DXHMKY].................................................................................................................................................2609 Failure Code [F313KA].................................................................................................................................................2611 Failure Code [F313KB].................................................................................................................................................2613 Failure Code [F314KA].................................................................................................................................................2614 Failure Code [F314KB].................................................................................................................................................2616 Failure Code [F315KB].................................................................................................................................................2618 Failure Code [F315KY].................................................................................................................................................2620 Failure Code [F316KB].................................................................................................................................................2622 Failure Code [F316KY].................................................................................................................................................2624 Failure Code [F318KB].................................................................................................................................................2626 Failure Code [F318KY].................................................................................................................................................2628 Failure Code [F31AKB].................................................................................................................................................2629 Failure Code [F31AKY].................................................................................................................................................2631 Failure Code [F31BKB].................................................................................................................................................2633 Failure Code [F31BKY].................................................................................................................................................2635 Failure Code [F31CKB].................................................................................................................................................2637 Failure Code [F31CKY].................................................................................................................................................2639 Failure Code [F31DKB].................................................................................................................................................2641 Failure Code [F31DKY].................................................................................................................................................2643 Failure Code [F31EKB].................................................................................................................................................2645 Failure Code [F31EKY].................................................................................................................................................2647 Failure Code [FS10ZE].................................................................................................................................................2649 Failure Code [LA00L3].................................................................................................................................................2650 Troubleshooting of Electrical System (E-Mode).............................................................................................................................2651 Engine Does Not Start (Engine Does Not Crank).........................................................................................................................2651 Manual Preheating System Does Not Operate.............................................................................................................................2660 Automatic Preheating System Does Not Operate..........................................................................................................................2663 While Preheating is in Operation, Preheating Monitor Does Not Come On.................................................................................................2666 The LCD Unit, LED Unit, and Meter Unit of the Machine Monitor Show Nothing............................................................................................2668 All of LCD Unit, LED Unit, and Meter Unit on Machine Monitor Show Nothing (For Machines to Which Emergency Engine Stop Switch is Installed)...........................2671 LCD Unit on Machine Monitor Shows Nothing.............................................................................................................................2674 Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers).................................................................................2677 LCD Screen on Machine Monitor Does Not Show Correctly.................................................................................................................2680 Meter Unit Display on Machine Monitor is Abnormal.....................................................................................................................2683 Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal..........................................................................................................2686 LED Unit Lamp on Machine Monitor is Abnormal..........................................................................................................................2689 Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly...................................................................2691 Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate............................................................................................2694 Switch Panel Buzzer of Machine Monitor is Abnormal....................................................................................................................2697 Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally......................................................................................2700 DEF Level is Not Shown Correctly......................................................................................................................................2701 Rearview Monitor Does Not Come On or Backlight Flickers...............................................................................................................2704 Rearview Monitor Images are Not Shown Clearly.........................................................................................................................2708 Rearview Monitor Brightness Cannot be Adjusted........................................................................................................................2712 Night Mode Lamp of Rearview Monitor is Abnormal.......................................................................................................................2716 Air Cleaner Clogging Indicator Lamp Does Not Come On..................................................................................................................2718 Radiator Coolant Level Caution Lamp Does Not Come On..................................................................................................................2720 Parking Brake Indicator Lamp Does Not Light When Parking Brake is Set to ON (Parking) Position........................................................................2722 Brake Oil Pressure Caution Lamp Does Not Come On When Front Brake Accumulator Oil Pressure is Low.....................................................................2726 Brake Oil Pressure Caution Lamp Does Not Come On When Rear Brake Accumulator Oil Pressure is Low......................................................................2727 Fuel Gauge Does Not Show Normally.....................................................................................................................................2728 Torque Converter Oil Temperature Gauge Does Not Increase, or Torque Converter Oil Temperature Caution Lamp Does Not Come On...........................................2730 Hydraulic Oil Temperature Gauge Does Not Rise or Hydraulic Oil Temperature Caution Lamp Does Not Come On..............................................................2731 Seatbelt Caution Lamp Does Not Show Normally..........................................................................................................................2733 Alarm Buzzer Does Not Operate.........................................................................................................................................2735 Alarm Buzzer Does Not Stop............................................................................................................................................2737 Kickdown Does Not Operate When Kickdown Switch is ON Position.........................................................................................................2738 Hold Does Not Operate When Hold Switch is on Position.................................................................................................................2740 Parking Brake Does Not Operate Even If It is Applied, or the Brake Drags in Forward or Reverse Travel When Parking Brake is Released..................................2742 Transmission Cut-off Mode is Not Selected or Not Released.............................................................................................................2746 Transmission Cut-off Setting Cannot be Released.......................................................................................................................2748 Directional Selector (FNR) Switch Mode is Not Selected or Not Released................................................................................................2750 Engine Mode Selector Function Does Not Operate Normally When Engine Power Mode Selector Switch is Operated............................................................2752 Flow of Loader Pump Does Not Increase from the Minimum Rate...........................................................................................................2754 ECSS Function Cannot be Selected or Cannot be Released................................................................................................................2755 ECSS Function Cannot be Selected or Cannot be Released (For AJSS Spec)................................................................................................2757 Horn Does Not Sound...................................................................................................................................................2759 Horn Does Not Sound (For AJSS Spec)...................................................................................................................................2762 Horn Does Not Stop....................................................................................................................................................2765 Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On................................................................................................................2768 Headlamp, Clearance Lamp, and Tail Lamp Do Not Light (For AJSS Spec)..................................................................................................2770 Clearance Lamp and Tail Lamp Do Not Come On or Go Out.................................................................................................................2772 Clearance Lamp and Tail Lamp Do Not Come On or Go Out (For AJSS Spec).................................................................................................2776 High and Low Beams of Headlamp Do Not Come On or Go Out...............................................................................................................2780 High and Low Beams of Headlamp Do Not Come On or Go Out (For AJSS Spec)...............................................................................................2784 Low Beam of Headlamp Does Not Come On or Go Out.......................................................................................................................2788 Low Beam of Headlamp Does Not Come On or Go Out (For AJSS Spec).......................................................................................................2790 High Beam of Headlamp Does Not Come On or Go Out......................................................................................................................2792 High Beam of Headlamp Does Not Come On or Go Out (For AJSS Spec)......................................................................................................2794 Front Working Lamp Does Not Come On or Go Out.........................................................................................................................2796 Rear Working Lamp Does Not Come On or Go Out..........................................................................................................................2800 Turn Signal Lamp and Hazard Lamp Do Not Come On or Go Out.............................................................................................................2804 All of Turn Signal Lamps and Hazard Lamps Do Not Come On or Go Out (For AJSS Spec)....................................................................................2807 Turn Signal Lamp Does Not Come On or Go Out...........................................................................................................................2810 Turn Signal Lamps Do Not Come On or Go Out (For AJSS Spec)............................................................................................................2813 Hazard Lamp Does Not Come On or Go Out................................................................................................................................2817 Brake Lamp Does Not Come On or Stays Lit..............................................................................................................................2821 Backup Lamp Does Not Come On or Stays Lit.............................................................................................................................2825 Backup Buzzer Does Not Sound or Continues to Sound....................................................................................................................2829 Front Wiper Does Not Operate..........................................................................................................................................2831 Front Wiper Does Not Operate (For AJSS Spec)..........................................................................................................................2835 Rear Wiper Does Not Operate...........................................................................................................................................2839 Rear Wiper Does Not Operate (For AJSS Spec)...........................................................................................................................2842 Fuel Feed Pump Does Not Operate or Stop Automatically.................................................................................................................2845 Window Washer Does Not Operate........................................................................................................................................2848 Window Washer Does Not Operate (For AJSS Spec)........................................................................................................................2851 KOMTRAX System Does Not Operate Correctly.............................................................................................................................2854 Auto-Greasing Pump Display Shows [FCS]................................................................................................................................2855 Auto-Greasing Pump Display Shows [FLL]................................................................................................................................2857 Auto-Greasing System Does Not Operate or Stop.........................................................................................................................2858 When Work Equipment Lock Switch is Operated, Work Equipment is Not Locked or Unlocked.................................................................................2860 Troubleshooting for Hydraulic and Mechanical Systems (H Mode).............................................................................................................2862 Information Shown in Troubleshooting Table (H-Mode)...................................................................................................................2862 Failure Mode and Cause Table..........................................................................................................................................2863 Machine Does Not Start................................................................................................................................................2886 Lockup is Not Released................................................................................................................................................2889 Torque Converter Lockup Clutch Does Not Engage........................................................................................................................2890 Travel Speed is Slow, Bucket Thrust Force is Weak, Gradability is Low, or Gear Speed Does Not Shift...................................................................2891 Strong Shocks are Made When You Start Machine or Shift Gears..........................................................................................................2894 Time Lag is Large When You Start Machine or Shift Gears...............................................................................................................2897 Torque Converter Oil Temperature is High..............................................................................................................................2900 Machine Does Not Turn (For Steering Wheel Spec).......................................................................................................................2902 Machine Does Not Turn (Joystick Steering Specification)...............................................................................................................2904 Machine Does Not Turn (AJSS Specification)............................................................................................................................2906 Turning Response is Unsatisfactory (For Steering Wheel Specification).................................................................................................2908 Turning Response is Unsatisfactory (Joystick Steering Specification)..................................................................................................2910 Turning Response is Unsatisfactory (AJSS Specification)...............................................................................................................2912 Steering Wheel is Heavy to Operate....................................................................................................................................2914 Machine Sways or Large Shocks are Made While Machine Turns (For Steering Wheel Specification).........................................................................2915 Machine Sways or Large Shocks are Made While Machine Turns (Joystick Steering Specification)..........................................................................2917 Machine Sways or Large Shocks are Made While Machine Turns (AJSS Specification).......................................................................................2919 Turning Radius is Different on the Left and Right.....................................................................................................................2921 Wheel Brakes Do Not Operate or are Weak...............................................................................................................................2922 Wheel Brakes are Not Released or Drag.................................................................................................................................2924 Parking Brake Does Not Operate or is Weak.............................................................................................................................2925 Parking Brake is Not Released or Drags................................................................................................................................2926 Boom Does Not Rise....................................................................................................................................................2928 Boom Moves Slow or Lacks Lifting Force................................................................................................................................2930 Rising Boom Slows Down at Specified Height............................................................................................................................2932 Lift Cylinders Can Not Hold Bucket on Ground..........................................................................................................................2933 Hydraulic Drift of Boom is Large......................................................................................................................................2934 Boom Moves Up and Down During Operation...............................................................................................................................2935 Bucket Does Not Tilt Back.............................................................................................................................................2936 Bucket Moves Slow or Lacks Tilt-Back Force............................................................................................................................2939 Bucket Slows Down During Tilt Back Operation..........................................................................................................................2941 Bucket Cylinder Does Not Hold Bucket on Ground........................................................................................................................2942 Hydraulic Drift of Bucket is Large....................................................................................................................................2943 Bucket Tilts Back and Forth When You Carry Load (Work Equipment Valve is in Hold).....................................................................................2944 Boom and Bucket Control Levers Do Not Move Smoothly and are Heavy to Move.............................................................................................2945 Boom and Bucket Control Levers Do Not Move Smoothly and are Heavy to Move (Multi-Function Mono-Lever Type)............................................................2946 Engine Speed Drops Largely or Engine Stops When You Operate Work Equipment............................................................................................2947 Large Shocks are Made When Work Equipment Starts to Move and Stops....................................................................................................2949 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves......................................................................................2951 ECSS Does Not Operate and Machine Pitches and Bounces.................................................................................................................2952 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)...........................................................................................................2953 Unusual Noise is Heard from Around Fan................................................................................................................................2954 Troubleshooting of Engine (S-Mode)........................................................................................................................................2955 Information Shown in Troubleshooting Table (S-Mode)...................................................................................................................2955 Engine Does Not Crank When Starting Switch is Turned to Start Position................................................................................................2956 Engine Cranks but No Exhaust Smoke Comes Out..........................................................................................................................2957 Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)...............................................................................2958 Engine Startability is Unsatisfactory.................................................................................................................................2959 Engine Does Not Pick Up Smoothly......................................................................................................................................2961 Engine Stops During Operation.........................................................................................................................................2963 Engine Does Not Rotate Smoothly.......................................................................................................................................2965 Engine Lacks Output (or Lacks Power)..................................................................................................................................2966 KDPF Becomes Clogged in a Short Time..................................................................................................................................2968 Engine Oil Consumption is Excessive...................................................................................................................................2970 Engine Oil Becomes Dirty Quickly......................................................................................................................................2971 Fuel Consumption is Excessive.........................................................................................................................................2972 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down).................................................................................................2973 Engine Oil Pressure Drops.............................................................................................................................................2974 Fuel Mixes Into Engine Oil............................................................................................................................................2976 Water Mixes Into Engine Oil (Milky)...................................................................................................................................2977 Coolant Temperature Increases Too High (Overheat).....................................................................................................................2978 Unusual Noise is Heard................................................................................................................................................2979 Vibration is Excessive................................................................................................................................................2980 Air Cannot be Bled from Fuel Circuit..................................................................................................................................2981 Active Regeneration is Done Frequently................................................................................................................................2982 Active Regeneration Continues Long....................................................................................................................................2984 White Smoke is Exhausted During Active Regeneration...................................................................................................................2985 DEF Consumption is Excessive..........................................................................................................................................2986 There is an Unusual Smell (Irritating Odor)...........................................................................................................................2988 Foreign Materials Enter DEF (DEF Increases)...........................................................................................................................2989 Troubleshooting for Auto-Greasing System..................................................................................................................................2990 Outline of Failure Display............................................................................................................................................2990 Troubleshooting for FCS...............................................................................................................................................2991 Troubleshooting for Auto-Greasing Pump................................................................................................................................2992 Replacement of Pump Element...........................................................................................................................................2995 Troubleshooting for Grease Supply System..............................................................................................................................2996 Replace Auto-Greasing Controller......................................................................................................................................2998 Assembly procedure when disassembled in troubleshooting...............................................................................................................2999 50 Disassembly and Assembly...................................................................................................................................................3001 Table of Contents.........................................................................................................................................................3002 Precautions Before Work...................................................................................................................................................3007 Abbreviation List.........................................................................................................................................................3008 Related Information on Disassembly and Assembly...........................................................................................................................3014 How to Read This Manual...............................................................................................................................................3014 Coating Materials List................................................................................................................................................3015 Special Tool List.....................................................................................................................................................3020 Sketches of Special Tools.............................................................................................................................................3046 Engine and Cooling System.................................................................................................................................................3055 Remove and Install Supply Pump Assembly...............................................................................................................................3055 How to Remove Supply Pump Assembly................................................................................................................................3056 How to Install Supply Pump Assembly...............................................................................................................................3058 Remove and Install Injector Assembly..................................................................................................................................3065 How to Remove Injector Assembly...................................................................................................................................3066 How to Install Injector Assembly..................................................................................................................................3076 Remove and Install Fuel Doser Assembly................................................................................................................................3091 How to Remove Fuel Doser Assembly.................................................................................................................................3091 How to Install Fuel Doser Assembly................................................................................................................................3092 Remove and Install Cylinder Head Assembly.............................................................................................................................3095 How to Remove Cylinder Head Assembly..............................................................................................................................3096 How to Install Cylinder Head Assembly.............................................................................................................................3106 Remove and Install EGR Valve Assembly.................................................................................................................................3122 How to Remove EGR Valve Assembly..................................................................................................................................3122 How to Install EGR Valve Assembly.................................................................................................................................3123 Remove and Install EGR Cooler Assembly................................................................................................................................3124 How to Remove EGR Cooler Assembly.................................................................................................................................3124 How to Install EGR Cooler Assembly................................................................................................................................3128 Remove and Install Starter Assembly...................................................................................................................................3132 How to Remove Starting Motor Assembly.............................................................................................................................3132 How to Install Starting Motor Assembly............................................................................................................................3133 Remove and Install Alternator Belt....................................................................................................................................3135 How to Remove Alternator Belt.....................................................................................................................................3135 How to Install Alternator Belt....................................................................................................................................3136 Remove and Install Radiator Assembly..................................................................................................................................3137 How to Remove Radiator Assembly...................................................................................................................................3138 How to Install Radiator Assembly..................................................................................................................................3143 Remove and Install Cooling Fan and Fan Motor Assembly.................................................................................................................3149 How to Remove Cooling Fan and Fan Motor Assembly..................................................................................................................3149 How to Install Cooling Fan and Fan Motor Assembly.................................................................................................................3152 Remove and Install Hydraulic Oil Cooler Assembly......................................................................................................................3155 How to Remove Hydraulic Oil Cooler Assembly.......................................................................................................................3155 How to Install Hydraulic Oil Cooler Assembly......................................................................................................................3160 Remove and Install Aftercooler Assembly...............................................................................................................................3167 How to Remove Aftercooler Assembly................................................................................................................................3168 How to Install Aftercooler Assembly...............................................................................................................................3172 Remove and Install Power Train Oil Cooler Assembly....................................................................................................................3178 How to Remove Power Train Oil Cooler Assembly.....................................................................................................................3178 How to Install Power Train Oil Cooler Assembly....................................................................................................................3180 Remove and Install Engine, Torque Converter, and Transmission Assembly................................................................................................3183 How to Remove Engine, Torque Converter, and Transmission Assembly.................................................................................................3184 How to Install Engine, Torque Converter, and Transmission Assembly................................................................................................3201 Disconnect and Connect Engine, Torque Converter, and Transmission Assembly............................................................................................3218 How to Disconnect Engine, Torque Converter, and Transmission Assembly.............................................................................................3218 How to Connect Engine, Torque Converter, and Transmission Assembly................................................................................................3219 Remove and Install Engine Front Oil Seal..............................................................................................................................3220 How to Remove Engine Front Oil Seal...............................................................................................................................3220 How to Install Engine Front Oil Seal..............................................................................................................................3221 Remove and Install Engine Rear Oil Seal...............................................................................................................................3225 How to Remove Engine Rear Oil Seal................................................................................................................................3225 How to Install Engine Rear Oil Seal...............................................................................................................................3227 Remove and Install Engine Hood Assembly...............................................................................................................................3233 How to Remove Engine Hood Assembly................................................................................................................................3233 How to Install Engine Hood Assembly...............................................................................................................................3237 Remove and Install KDPF Assembly......................................................................................................................................3241 How to Remove KDPF Assembly.......................................................................................................................................3242 How to Install KDPF Assembly......................................................................................................................................3245 Disassemble and Assemble KDPF Assembly................................................................................................................................3249 How to Disassemble KDPF Assembly..................................................................................................................................3249 How to Assemble KDPF Assembly.....................................................................................................................................3253 Remove and Install KDPF and SCR Assembly..............................................................................................................................3259 How to Remove KDPF and SCR Assembly...............................................................................................................................3259 How to Install KDPF and SCR Assembly..............................................................................................................................3262 Remove and Install Fuel Tank Assembly.................................................................................................................................3266 How to Remove Fuel Tank Assembly..................................................................................................................................3266 How to Install Fuel Tank Assembly.................................................................................................................................3269 Remove and Install DEF Tank Assembly..................................................................................................................................3272 How to Remove DEF Tank Assembly...................................................................................................................................3272 How to Install DEF Tank Assembly..................................................................................................................................3281 Remove and Install DEF Tank Sensor Flange Assembly....................................................................................................................3288 How to Remove DEF Tank Sensor Flange Assembly.....................................................................................................................3288 How to Install DEF Tank Sensor Flange Assembly....................................................................................................................3290 Remove and Install DEF Tank Sensor....................................................................................................................................3292 How to Remove DEF Tank Sensor.....................................................................................................................................3292 How to Install DEF Tank Sensor....................................................................................................................................3293 Remove and Install DEF Tank Strainer..................................................................................................................................3300 How to Remove DEF Tank Strainer...................................................................................................................................3300 How to Install DEF Tank Strainer..................................................................................................................................3301 Remove and Install SCR Assembly.......................................................................................................................................3302 How to Remove SCR Assembly........................................................................................................................................3302 How to Install SCR Assembly.......................................................................................................................................3305 Remove and Install KCCV Assembly......................................................................................................................................3310 How to Remove KCCV Assembly.......................................................................................................................................3310 How to Install KCCV Assembly......................................................................................................................................3312 Remove and Install VGT Assembly.......................................................................................................................................3315 How to Remove VGT Assembly........................................................................................................................................3315 How to Install VGT Assembly.......................................................................................................................................3318 Remove and Install DEF Mixing Tube....................................................................................................................................3322 How to Remove DEF Mixing Tube.....................................................................................................................................3322 How to Install DEF Mixing Tube....................................................................................................................................3325 Remove and Install DEF Injector.......................................................................................................................................3329 How to Remove DEF Injector........................................................................................................................................3329 How to Install DEF Injector.......................................................................................................................................3332 Remove and Install DEF Pump...........................................................................................................................................3335 How to Remove DEF Pump............................................................................................................................................3335 How to Install DEF Pump...........................................................................................................................................3338 Remove and Install DEF Hose...........................................................................................................................................3341 How to Remove DEF Hose............................................................................................................................................3341 How to Install DEF Hose...........................................................................................................................................3348 Remove and Install Air Cleaner Assembly...............................................................................................................................3356 How to Remove Air Cleaner Assembly................................................................................................................................3356 How to Install Air Cleaner Assembly...............................................................................................................................3359 Remove and Install Air Conditioner Compressor Assembly................................................................................................................3362 How to Remove Air Conditioner Compressor Assembly.................................................................................................................3362 How to Install Air Conditioner Compressor Assembly................................................................................................................3363 Remove and Install Air Conditioner Condenser Assembly.................................................................................................................3366 How to Remove Air Conditioner Condenser Assembly..................................................................................................................3366 How to Install Air Conditioner Condenser Assembly.................................................................................................................3367 Power Train...............................................................................................................................................................3369 Disconnect and Connect Torque Converter and Transmission Assembly.....................................................................................................3369 How to Disconnect Torque Converter and Transmission Assembly......................................................................................................3369 How to Connect Torque Converter and Transmission Assembly.........................................................................................................3375 Remove and Install Front Differential Assembly........................................................................................................................3381 How to Remove Front Differential Assembly.........................................................................................................................3381 How to Install Front Differential Assembly........................................................................................................................3382 Disassemble and Assemble Differential Assembly (Specification with LSD)...............................................................................................3385 How to Disassemble Differential Assembly (Specification with LSD).................................................................................................3386 How to Assemble Differential Assembly (Specification with LSD)....................................................................................................3392 Disassemble and Assemble Differential Assembly (Specification Without LSD)............................................................................................3405 How to Disassemble Differential Assembly (Specification Without LSD)..............................................................................................3406 How to Assemble Differential Assembly (Specification Without LSD).................................................................................................3411 Disassemble and Assemble Torque Converter Assembly....................................................................................................................3421 How to Disassemble Torque Converter Assembly......................................................................................................................3422 How to Assemble Torque Converter Assembly.........................................................................................................................3430 Disassemble and Assemble Input Transfer Assembly......................................................................................................................3441 How to Disassemble Input Transfer Assembly........................................................................................................................3441 How to Assemble Input Transfer Assembly...........................................................................................................................3445 Disassemble and Assemble Transmission Assembly........................................................................................................................3451 How to Disassemble Transmission Assembly..........................................................................................................................3453 How to Assemble Transmission Assembly.............................................................................................................................3472 Disassemble and Assemble Transfer and Parking Brake Assembly..........................................................................................................3494 How to Disassemble Transfer and Parking Brake Assembly............................................................................................................3496 How to Assemble Transfer and Parking Brake Assembly...............................................................................................................3506 Remove and Install Front Axle Assembly................................................................................................................................3521 How to Remove Front Axle Assembly.................................................................................................................................3521 How to Install Front Axle Assembly................................................................................................................................3523 Remove and Install Rear Axle Assembly.................................................................................................................................3525 How to Remove Rear Axle Assembly..................................................................................................................................3525 How to Install Rear Axle Assembly.................................................................................................................................3528 Disassemble and Assemble Final Drive Assembly (Front, Rear)...........................................................................................................3530 How to Disassemble Final Drive Assembly (Front, Rear).............................................................................................................3530 How to Assemble Final Drive Assembly (Front, Rear)................................................................................................................3533 Steering System...........................................................................................................................................................3539 Remove and Install Steering Valve Assembly............................................................................................................................3539 How to Remove Steering Valve Assembly.............................................................................................................................3539 How to Install Steering Valve Assembly............................................................................................................................3541 Remove and Install Rotary Valve Assembly (For AJSS Spec)..............................................................................................................3543 How to Remove Rotary Valve Assembly...............................................................................................................................3543 How to Install Rotary Valve Assembly..............................................................................................................................3550 Brake System..............................................................................................................................................................3560 Disassemble and Assemble Slack Adjuster Assembly......................................................................................................................3560 How to Assemble Slack Adjuster Assembly...........................................................................................................................3560 Disassemble and Assemble Brake Accumulator Charge Valve Assembly......................................................................................................3561 How to Assemble Brake Accumulator Charge Valve Assembly...........................................................................................................3561 Remove and Install Brake Assembly (Front, Rear).......................................................................................................................3562 How to Remove Brake Assembly (Front, Rear)........................................................................................................................3562 How to Install Brake Assembly (Front, Rear).......................................................................................................................3564 Disassemble and Assemble Brake Assembly (Front, Rear).................................................................................................................3566 How to Disassemble Brake Assembly (Front, Rear)...................................................................................................................3567 How to Assemble Wheel Brake Assembly (Front, Rear)................................................................................................................3569 Undercarriage and Frame...................................................................................................................................................3575 Remove and Install Center Hinge Pin...................................................................................................................................3575 How to Remove Center Hinge Pin....................................................................................................................................3576 How to Install Center Hinge Pin...................................................................................................................................3582 Remove and Install Counterweight Assembly.............................................................................................................................3591 How to Remove Counterweight Assembly..............................................................................................................................3591 How to Install Counterweight Assembly.............................................................................................................................3593 Remove and Install Full-Length Fender Assembly........................................................................................................................3596 How to Remove Full-Length Fender Assembly.........................................................................................................................3596 How to Install Full-Length Fender Assembly........................................................................................................................3597 Hydraulic System..........................................................................................................................................................3599 Remove and Install Hydraulic Tank Assembly............................................................................................................................3599 How to Remove Hydraulic Tank Assembly.............................................................................................................................3599 How to Install Hydraulic Tank Assembly............................................................................................................................3605 Remove and Install Work Equipment Pump Assembly.......................................................................................................................3611 How to Remove Work Equipment Pump Assembly........................................................................................................................3612 How to Install Work Equipment Pump Assembly.......................................................................................................................3615 Remove and Install Steering Pump and Power Train Pump Assembly........................................................................................................3619 How to Remove Steering Pump and Power Train Pump Assembly.........................................................................................................3620 How to Install Steering Pump and Power Train Pump Assembly........................................................................................................3624 Remove and Install Diverter Valve Assembly............................................................................................................................3628 How to Remove Diverter Valve Assembly.............................................................................................................................3628 How to Install Diverter Valve Assembly............................................................................................................................3631 Remove and Install Cooling Fan Pump Assembly..........................................................................................................................3633 How to Remove Cooling Fan Pump Assembly...........................................................................................................................3633 How to Install Cooling Fan Pump Assembly..........................................................................................................................3636 Remove and Install Control Valve Assembly.............................................................................................................................3638 How to Remove Control Valve Assembly..............................................................................................................................3638 How to Install Control Valve Assembly.............................................................................................................................3641 Disassemble and Assemble Steering Cylinder Assembly...................................................................................................................3644 How to Disassemble Steering Cylinder Assembly.....................................................................................................................3644 How to Assemble Steering Cylinder Assembly........................................................................................................................3646 Disassemble and Assemble Work Equipment Cylinder Assembly.............................................................................................................3649 How to Disassemble Work Equipment Cylinder Assembly...............................................................................................................3649 How to Assemble Work Equipment Cylinder Assembly..................................................................................................................3651 Work Equipment............................................................................................................................................................3656 Remove and Install Work Equipment Assembly............................................................................................................................3656 How to Remove Work Equipment Assembly.............................................................................................................................3656 How to Install Work Equipment Assembly............................................................................................................................3660 CAB Related Parts.........................................................................................................................................................3664 Remove and Install Operator Cab Assembly..............................................................................................................................3664 How to Remove Operator Cab Assembly...............................................................................................................................3665 How to Install Operator Cab Assembly..............................................................................................................................3674 Remove and Install Operator Cab Glass (Adhered Glass).................................................................................................................3684 How to Remove Operator Cab Glass (Adhered Glass)..................................................................................................................3684 How to Install Operator Cab Glass (Adhered Glass).................................................................................................................3685 Remove and Install Air Conditioner Unit Assembly......................................................................................................................3694 How to Remove Air Conditioner Unit Assembly.......................................................................................................................3694 How to Install Air Conditioner Unit Assembly......................................................................................................................3700 Remove and Install Operator Seat Assembly.............................................................................................................................3705 How to Remove Operator Seat Assembly..............................................................................................................................3705 How to Install Operator Seat Assembly.............................................................................................................................3707 Remove and Install Switch Assembly of AJSS Lever......................................................................................................................3709 How to Remove Switch Assembly of AJSS Lever.......................................................................................................................3709 How to Install Switch Assembly of AJSS Lever......................................................................................................................3711 How to Remove and Install Seat Belt...................................................................................................................................3715 How to Remove Seat Belt...........................................................................................................................................3715 How to Install Seatbelt...........................................................................................................................................3715 Electrical System.........................................................................................................................................................3717 Remove and Install Engine Controller Assembly.........................................................................................................................3717 How to Remove Engine Controller Assembly..........................................................................................................................3717 How to Install Engine Controller Assembly.........................................................................................................................3720 Remove and Install Work Equipment Controller Assembly.................................................................................................................3723 How to Remove Work Equipment Controller Assembly..................................................................................................................3723 How to Install Work Equipment Controller Assembly.................................................................................................................3724 Remove and Install Transmission Controller Assembly...................................................................................................................3727 How to Remove Transmission Controller Assembly....................................................................................................................3727 How to Install Transmission Controller Assembly...................................................................................................................3727 Remove and Install Monitor Controller Assembly........................................................................................................................3729 How to Remove Monitor Controller Assembly.........................................................................................................................3729 How to Install Monitor Controller Assembly........................................................................................................................3731 Remove and Install Machine Monitor Assembly...........................................................................................................................3733 How to Remove Machine Monitor Assembly............................................................................................................................3733 How to Install Machine Monitor Assembly...........................................................................................................................3734 Remove and Install Mass Air Flow and Temperature Sensor...............................................................................................................3736 How to Remove Mass Air Flow and Temperature Sensor................................................................................................................3736 How to Install Mass Air Flow and Temperature Sensor...............................................................................................................3737 Remove and Install KCCV Crankcase Pressure Sensor.....................................................................................................................3739 How to Remove KCCV Crankcase Pressure Sensor......................................................................................................................3739 How to Install KCCV Crankcase Pressure Sensor.....................................................................................................................3740 Remove and Install SCR Temperature Sensor.............................................................................................................................3742 How to Remove SCR Temperature Sensor..............................................................................................................................3742 How to Install SCR Temperature Sensor.............................................................................................................................3744 Remove and Install KOMTRAX Terminal Assembly..........................................................................................................................3746 How to Remove KOMTRAX Terminal Assembly...........................................................................................................................3746 How to Install KOMTRAX Terminal Assembly..........................................................................................................................3747 Remove and Install Gateway Function Controller Assembly...............................................................................................................3748 How to Remove Gateway Function Controller Assembly................................................................................................................3748 How to Install Gateway Function Controller Assembly...............................................................................................................3749 Remove and Install Communication Terminal.............................................................................................................................3750 How to Remove Communication Terminal..............................................................................................................................3750 How to Install Communication Terminal.............................................................................................................................3755 60 Maintenance Standard.......................................................................................................................................................3761 Table of Contents.........................................................................................................................................................3762 Abbreviation List.........................................................................................................................................................3763 Engine and Cooling System.................................................................................................................................................3769 Maintenance Standard for Engine Mount.................................................................................................................................3769 Maintenance Standard for Joint........................................................................................................................................3771 Maintenance Standard for Brake and Cooling Fan Pump...................................................................................................................3772 Maintenance Standard for Servo Valve of Brake and Cooling Fan Pump................................................................................................3774 Maintenance Standard for Cooling Fan Motor............................................................................................................................3775 Power Train...............................................................................................................................................................3777 Maintenance Standard for Drive Shaft..................................................................................................................................3777 Maintenance Standard for Center Support...........................................................................................................................3778 Maintenance Standard for Torque Converter.............................................................................................................................3779 Maintenance Standard for Lockup Clutch ECMV...........................................................................................................................3784 Maintenance Standard for Transmission.................................................................................................................................3785 Maintenance Standard for Transmission Control Valve...................................................................................................................3793 Maintenance Standard for Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV...................................................................................3794 Maintenance Standard for Torque Converter Regulator Valve.............................................................................................................3795 Maintenance Standard for Main Relief Valve, Torque Converter Relief Valve, and Main Flow Selector Valve...............................................................3796 Maintenance Standard for Transmission Lubrication Relief Valve........................................................................................................3798 Maintenance Standard for Front Axle...................................................................................................................................3799 Maintenance Standard for Rear Axle....................................................................................................................................3800 Maintenance Standard for Front Conventional Differential..............................................................................................................3801 Maintenance Standard for Front Limited Slip Differential..............................................................................................................3805 Maintenance Standard for Final Drive..................................................................................................................................3807 Steering System...........................................................................................................................................................3809 Maintenance Standard for Steering Column..............................................................................................................................3809 Maintenance Standard for Steering Pump................................................................................................................................3810 Maintenance Standard for Servo Valve of Steering Pump.............................................................................................................3813 Maintenance Standard for Steering Valve...............................................................................................................................3814 Maintenance Standard for Steering Cylinder............................................................................................................................3815 Maintenance Standard for Diverter Valve...............................................................................................................................3817 Maintenance Standard for Secondary Steering Pump......................................................................................................................3818 Brake System..............................................................................................................................................................3819 Maintenance Standard for Charge Valve.................................................................................................................................3819 Maintenance Standard for Brake Circuit Accumulator....................................................................................................................3821 Maintenance Standard for Brake Valve..................................................................................................................................3822 Maintenance Standard for Slack Adjuster...............................................................................................................................3823 Maintenance Standard for Brake........................................................................................................................................3824 Maintenance Standard for Parking Brake................................................................................................................................3826 Maintenance Standard for Parking Brake Solenoid Valve.................................................................................................................3828 Undercarriage and Frame...................................................................................................................................................3829 Maintenance Standard for Frame, Axle Mount and Center Hinge Pin.......................................................................................................3829 Hydraulic System..........................................................................................................................................................3834 Maintenance Standard for Hydraulic Tank...............................................................................................................................3834 Maintenance Standard for Work Equipment Pump..........................................................................................................................3835 Maintenance Standard for Power Train Charge Duplex Pump...............................................................................................................3837 Maintenance Standard for Control Valve................................................................................................................................3839 Maintenance Standard for Control Valve (Stone-Handling Specification).................................................................................................3848 Maintenance Standard for Work Equipment Lock Solenoid Valve...........................................................................................................3857 Work Equipment............................................................................................................................................................3858 Maintenance Standard for Work Equipment Linkage.......................................................................................................................3858 Maintenance Standard for Bucket.......................................................................................................................................3862 Maintenance Standard for Lift Cylinder................................................................................................................................3864 Maintenance Standard for Bucket Cylinder..............................................................................................................................3865 80 Appendix...................................................................................................................................................................3867 Table of Contents.........................................................................................................................................................3868 Precautions Before Work...................................................................................................................................................3870 Abbreviation List.........................................................................................................................................................3871 Air Conditioner System....................................................................................................................................................3877 Precautions for Refrigerant...........................................................................................................................................3877 Air Conditioner Component.............................................................................................................................................3878 Specifications of Air Conditioner.....................................................................................................................................3880 Structure and Function of Refrigeration Cycle.........................................................................................................................3881 Outline of Refrigeration Cycle........................................................................................................................................3882 Component Parts of Air Conditioner System.................................................................................................................................3884 Air Conditioner Unit..................................................................................................................................................3884 Configuration Diagram of Air Conditioner Unit.....................................................................................................................3884 Function of Air Conditioner Unit..................................................................................................................................3885 Component Parts of Air Conditioner Unit...............................................................................................................................3886 Function of Evaporator as Air Conditioner Unit Component..........................................................................................................3886 Function of Inside Air Temperature Sensor as Air Conditioner Unit Component.......................................................................................3886 Function of Blower Amplifier as Air Conditioner Unit Component....................................................................................................3887 Function of Blower OFF Relay as Air Conditioner Unit Component....................................................................................................3887 Function of Compressor Clutch Relay as Air Conditioner Unit Component.............................................................................................3887 Function of Heater Core as Air Conditioner Unit Component.........................................................................................................3887 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component.......................................................................................3887 Function of Servo Motor as Air Conditioner Unit Component.........................................................................................................3887 Function of Expansion Valve as Air Conditioner Unit Component.....................................................................................................3888 Function of Dual Pressure Switch..................................................................................................................................3888 Air Conditioner Controller............................................................................................................................................3889 Structure of Air Conditioner Controller...........................................................................................................................3889 Compressor............................................................................................................................................................3890 Structure of Compressor...........................................................................................................................................3890 Specifications of Compressor......................................................................................................................................3890 Function of Compressor............................................................................................................................................3890 Condenser.............................................................................................................................................................3891 Structure of Condenser............................................................................................................................................3891 Specifications of Condenser.......................................................................................................................................3891 Function of Condenser.............................................................................................................................................3891 Receiver Drier........................................................................................................................................................3892 Structure of Receiver Dryer.......................................................................................................................................3892 Specifications of Receiver Dryer..................................................................................................................................3892 Function of Receiver Dryer........................................................................................................................................3892 Air Conditioner Related Sensors.......................................................................................................................................3893 Function of Sunlight Sensor.......................................................................................................................................3893 Function of Outside Air Temperature Sensor........................................................................................................................3893 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner...............................................................................................3894 Circuit Diagram and Configuration of Connector Pins of Air Conditioner....................................................................................................3896 System Diagram of Air Conditioner.........................................................................................................................................3899 Input and Output Signals of Air Conditioner Controller................................................................................................................3900 Function of Air Conditioner Controller............................................................................................................................3901 Locations of Air Conditioner Parts and Layout of Connectors...............................................................................................................3902 Examine Air Conditioner with Self-Diagnosis Function......................................................................................................................3908 Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor...................................................................................3909 Examine Temperature Control Function......................................................................................................................................3911 How to Examine Temperature Control Function...........................................................................................................................3911 Examine Vent (Mode) Changeover............................................................................................................................................3913 How to Examine Vent (Mode) Changeover.................................................................................................................................3913 Examine Fresh/Recirc Air Changeover.......................................................................................................................................3915 How to Examine Fresh/Recirc Air Changeover............................................................................................................................3915 Examine Evaporator Temperature Sensor.....................................................................................................................................3917 Examine Relay.............................................................................................................................................................3919 How to Examine Relay..................................................................................................................................................3919 Air Conditioner Troubleshooting Chart 1...................................................................................................................................3921 Air Conditioner Troubleshooting Chart 2...................................................................................................................................3922 Information Shown in Troubleshooting Table................................................................................................................................3925 Failure Code [879AKA].....................................................................................................................................................3926 Failure Code [879AKB].....................................................................................................................................................3928 Failure Code [879BKA].....................................................................................................................................................3930 Failure Code [879BKB].....................................................................................................................................................3932 Failure Code [879CKA].....................................................................................................................................................3934 Failure Code [879CKB].....................................................................................................................................................3936 Failure Code [879DKZ].....................................................................................................................................................3938 Failure Code [879EMC].....................................................................................................................................................3940 Failure Code [879FMC].....................................................................................................................................................3943 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)................................................................................................3946 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled).................................................................................................3949 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)........................................................................................3952 Troubleshooting for Fresh/Recirc Air Changeover...........................................................................................................................3956 Troubleshooting by Gauge Pressure.........................................................................................................................................3958 Connect Service Tool......................................................................................................................................................3961 How to Connect Service Tool...........................................................................................................................................3962 Precautions for Disconnection and Connection of Air Conditioner Piping....................................................................................................3963 Handle Compressor Oil.....................................................................................................................................................3965 90 Circuit Diagrams...........................................................................................................................................................3967 Table of Contents.........................................................................................................................................................3968 Abbreviation List.........................................................................................................................................................3971 Hydraulic Circuit Diagram.................................................................................................................................................3977 Symbols Used in Hydraulic Circuit Diagram.............................................................................................................................3977 Hydraulic Circuit Diagram (For Steering Wheel and Joystick Steering Spec).............................................................................................3981 Hydraulic Circuit Diagram (For AJSS Spec).............................................................................................................................3983 Hydraulic Circuit Diagram (Stone-Handling Specification)..............................................................................................................3985 Power Train Hydraulic Circuit Diagram.................................................................................................................................3987 Hydraulic Circuit Diagram of Brake System.............................................................................................................................3989 Hydraulic Auto-Greasing Diagram.......................................................................................................................................3991 Electrical Circuit Diagram................................................................................................................................................3993 Symbols Used in Electric Circuit Diagram..............................................................................................................................3993 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (1/6)...........................................................................................3997 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (2/6)...........................................................................................3999 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (3/6)...........................................................................................4001 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (4/6)...........................................................................................4003 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (5/6)...........................................................................................4005 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (6/6)...........................................................................................4007 Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (Machine with KOMTRAX Terminal) (1/6)...................................................4009 Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (Machine with KOMTRAX Terminal) (2/6)...................................................4011 Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (Machine with KOMTRAX Terminal) (3/6)...................................................4013 Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (Machine with KOMTRAX Terminal) (4/6)...................................................4015 Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (Machine with KOMTRAX Terminal) (5/6)...................................................4017 Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (Machine with KOMTRAX Terminal) (6/6)...................................................4019 Electrical Circuit Diagram of Machine (Machine with gateway function controller) (1/6)................................................................................4021 Electrical Circuit Diagram of Machine (Machine with gateway function controller) (2/6)................................................................................4023 Electrical Circuit Diagram of Machine (Machine with gateway function controller) (3/6)................................................................................4025 Electrical Circuit Diagram of Machine (Machine with gateway function controller) (4/6)................................................................................4027 Electrical Circuit Diagram of Machine (Machine with gateway function controller) (5/6)................................................................................4029 Electrical Circuit Diagram of Machine (Machine with gateway function controller) (6/6)................................................................................4031 Electrical Circuit Diagram of Floor (For Steering Wheel and Joystick Steering Spec) (Machine with KOMTRAX Terminal) (1/10)............................................4033 Electrical Circuit Diagram of Floor (For Steering Wheel and Joystick Steering Spec) (Machine with KOMTRAX Terminal) (2/10)............................................4035 Electrical Circuit Diagram of Floor (For Steering Wheel and Joystick Steering Spec) (Machine with KOMTRAX Terminal) (3/10)............................................4037 Electrical Circuit Diagram of Floor (For Steering Wheel and Joystick Steering Spec) (Machine with KOMTRAX Terminal) (4/10)............................................4039 Electrical Circuit Diagram of Floor (For Steering Wheel and Joystick Steering Spec) (Machine with KOMTRAX Terminal) (5/10)............................................4041 Electrical Circuit Diagram of Floor (For Steering Wheel and Joystick Steering Spec) (Machine with KOMTRAX Terminal) (6/10)............................................4043 Electrical Circuit Diagram of Floor (For Steering Wheel and Joystick Steering Spec) (Machine with KOMTRAX Terminal) (7/10)............................................4045 Electrical Circuit Diagram of Floor (For Steering Wheel and Joystick Steering Spec) (Machine with KOMTRAX Terminal) (8/10)............................................4047 Electrical Circuit Diagram of Floor (For Steering Wheel and Joystick Steering Spec) (Machine with KOMTRAX Terminal) (9/10)............................................4049 Electrical Circuit Diagram of Floor (For Steering Wheel and Joystick Steering Spec) (Machine with KOMTRAX Terminal) (10/10)...........................................4051 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (1/9).............................................................................4053 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (2/9).............................................................................4055 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (3/9).............................................................................4057 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (4/9).............................................................................4059 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (5/9).............................................................................4061 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (6/9).............................................................................4063 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (7/9).............................................................................4065 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (8/9).............................................................................4067 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (9/9).............................................................................4069 Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (Machine with KOMTRAX Terminal) (1/8).....................................................4071 Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (Machine with KOMTRAX Terminal) (2/8).....................................................4073 Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (Machine with KOMTRAX Terminal) (3/8).....................................................4075 Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (Machine with KOMTRAX Terminal) (4/8).....................................................4077 Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (Machine with KOMTRAX Terminal) (5/8).....................................................4079 Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (Machine with KOMTRAX Terminal) (6/8).....................................................4081 Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (Machine with KOMTRAX Terminal) (7/8).....................................................4083 Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (Machine with KOMTRAX Terminal) (8/8).....................................................4085 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (1/11).....4087 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (2/11).....4089 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (3/11).....4091 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (4/11).....4093 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (5/11).....4095 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (6/11).....4097 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (7/11).....4099 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (8/11).....4101 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (9/11).....4103 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (10/11)....4105 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (11/11)....4107 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (1/11).......4109 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (2/11).......4111 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (3/11).......4113 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (4/11).......4115 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (5/11).......4117 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (6/11).......4119 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (7/11).......4121 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (8/11).......4123 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (9/11).......4125 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (10/11)......4127 Electrical Circuit Diagram of Floor (For European Union, Turkey and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (11/11)......4129 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (1/10)............................4131 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (2/10)............................4133 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (3/10)............................4135 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (4/10)............................4137 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (5/10)............................4139 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (6/10)............................4141 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (7/10)............................4143 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (8/10)............................4145 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (9/10)............................4147 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90278 to 90960) (10/10)...........................4149 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (1/10)..............................4151 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (2/10)..............................4153 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (3/10)..............................4155 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (4/10)..............................4157 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (5/10)..............................4159 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (6/10)..............................4161 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (7/10)..............................4163 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (8/10)..............................4165 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (9/10)..............................4167 Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 90961 and Up) (10/10).............................4169 Index..........................................................................................................................................................................4171
DESCRIPTION:
KOMATSU WA500-8E0 WHEEL LOADER SHOP MANUAL SEN06755-08 – 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 31/12/24
