Komatsu WA500-8E0 Wheel Loader Shop Manual VENBM55000 PDF

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Komatsu WA500-8E0 Wheel Loader Shop Manual VENBM55000 – PDF DOWNLOAD

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Komatsu WA500-8E0 Wheel Loader Shop Manual VENBM55000 – PDF DOWNLOAD 

Language : English
Pages : 3996
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA500-8E0 Wheel Loader Shop Manual VENBM55000 – PDF DOWNLOAD

SERIAL NUMBERS H50151 and up

00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 28
FOREWORD, SAFETY, BASIC INFORMATION 34
HOW TO READ THE SHOP MANUAL 34
SAFETY NOTICE FOR OPERATION 36
PRECAUTIONS TO PREVENT FIRE 44
ACTIONS IF FIRE OCCURS 46
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 47
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 48
PRECAUTIONS FOR DEF 49
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 49
PRECAUTIONS FOR ADDING 49
PRECAUTIONS FOR STORING 49
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 49
THE OTHER PRECAUTIONS 49
STORE AdBlue/DEF 50
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 51
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 54
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 61
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 63
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 64
PRACTICAL USE OF KOMTRAX 65
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 66
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 66
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 67
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 68
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 70
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 74
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 75
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 77
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 78
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 80
HOW TO READ ELECTRICAL WIRE CODE 81
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 85
STANDARD TIGHTENING TORQUE TABLE 88
CONVERSION TABLE 95
01 SPECIFICATIONS 101
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
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 AdBlue/DEF SYSTEM 137
INDUCEMENT STRATEGY 139
COMPONENT PARTS OF UREA SCR SYSTEM 153
AdBlue/DEF MIXING TUBE 153
SCR ASSEMBLY 153
AdBlue/DEF TANK 156
AdBlue/DEF PUMP 158
AdBlue/DEF INJECTOR 159
AdBlue/DEF HOSE 160
AdBlue/DEF TANK HEATING VALVE 161
BOOT-UP SYSTEM 162
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 162
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 164
LAYOUT DRAWING OF BOOT-UP SYSTEM (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) 166
LAYOUT DRAWING OF BOOT-UP SYSTEM (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) 168
SYSTEM OPERATING LAMP SYSTEM 170
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 170
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 170
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 170
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 171
BATTERY DISCONNECT SWITCH 173
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH 173
FUNCTION OF BATTERY DISCONNECT SWITCH 173
PREHEATING SYSTEM 175
PREHEATING SYSTEM DIAGRAM 175
FUNCTION OF AUTOMATIC PREHEATING SYSTEM 175
OPERATION OF AUTOMATIC PREHEATING SYSTEM 175
FUNCTION OF MANUAL PREHEATING SYSTEM 176
OPERATION OF MANUAL PREHEATING SYSTEM 176
ENGINE SHUTDOWN SECONDARY SWITCH 177
LAYOUT DRAWING OF ENGINE SHUTDOWN SECONDARY SWITCH 177
FUNCTION OF ENGINE SHUTDOWN SECONDARY SWITCH 177
OPERATION OF ENGINE SHUTDOWN SECONDARY SWITCH 178
ENGINE SYSTEM 179
LAYOUT DRAWING OF ENGINE SYSTEM 179
FUNCTION OF ENGINE SYSTEM 180
ENGINE CONTROL SYSTEM 181
ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 181
ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 182
FUNCTION OF ENGINE CONTROL SYSTEM 183
OPERATION OF ENGINE CONTROL SYSTEM 186
ENGINE POWER MODE SELECTOR SYSTEM 188
ENGINE POWER MODE SELECTOR SYSTEM DIAGRAM 188
FUNCTION OF ENGINE POWER MODE SELECTOR SYSTEM 188
OPERATION OF ENGINE POWER MODE SELECTOR SYSTEM 188
AUTOMATIC IDLE STOP SYSTEM 189
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 189
RPM SET 190
FUNCTION OF RPM SET 190
OPERATION OF RPM SET 191
COMPONENT PARTS OF ENGINE SYSTEM 194
JOINT 194
VGT 194
EGR SYSTEM 198
EGR VALVE 200
EGR COOLER 202
KCCV SYSTEM 204
KCCV VENTILATOR 206
KDPF 209
COOLING SYSTEM 213
LAYOUT DRAWING OF COOLING SYSTEM 213
SPECIFICATIONS OF COOLING SYSTEM 213
COOLING FAN CONTROL SYSTEM 215
COOLING FAN CONTROL SYSTEM DIAGRAM 215
FUNCTION OF COOLING FAN CONTROL SYSTEM 215
COMPONENT PARTS OF COOLING SYSTEM 220
BRAKE AND COOLING FAN PUMP 220
COOLING FAN MOTOR 227
CONTROL SYSTEM 234
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 234
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 236
MACHINE MONITOR SYSTEM 238
MACHINE MONITOR SYSTEM DIAGRAM 238
FUNCTION OF MACHINE MONITOR SYSTEM 238
REARVIEW MONITOR SYSTEM 240
REARVIEW MONITOR SYSTEM DIAGRAM 240
FUNCTION OF REARVIEW MONITOR SYSTEM 240
KOMTRAX SYSTEM 241
KOMTRAX SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 241
SYSTEM DIAGRAM OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 241
FUNCTION OF KOMTRAX SYSTEM 242
LOAD METER SYSTEM 243
LOAD METER SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 243
LOAD METER SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 244
FUNCTION OF LOAD METER SYSTEM 244
COMPONENT PARTS OF CONTROL SYSTEM 250
MACHINE MONITOR 250
SWITCH PANEL 269
REARVIEW MONITOR 270
REARVIEW CAMERA 271
KOMTRAX TERMINAL 272
GATEWAY FUNCTION CONTROLLER 274
COMMUNICATION TERMINAL 277
TRANSMISSION CONTROLLER 279
WORK EQUIPMENT CONTROLLER 283
MONITOR CONTROLLER 287
CAN TERMINATING RESISTOR 291
ENGINE CONTROLLER 292
ACCELERATOR PEDAL 298
FUEL FEED PUMP 300
FUEL FEED PUMP SWITCH 301
HYDRAULIC SYSTEM 302
LAYOUT DRAWING OF HYDRAULIC SYSTEM 302
CLSS 303
STRUCTURE OF CLSS 303
FUNCTION OF CLSS 304
WORK EQUIPMENT PUMP CONTROL SYSTEM 307
SWASH PLATE CONTROL FUNCTION OF WORK EQUIPMENT PUMP 307
PICKUP ASSISTANCE CONTROL FUNCTION WHEN ENGINE SPEED IS LOW 307
COMPONENT PARTS OF HYDRAULIC SYSTEM 308
HYDRAULIC TANK 308
WORK EQUIPMENT PUMP 311
STEERING PUMP 329
POWER TRAIN CHARGE DUPLEX PUMP 342
CONTROL VALVE 343
POWER TRAIN SYSTEM 377
LAYOUT DRAWING OF POWER TRAIN SYSTEM 377
OPERATION OF POWER TRAIN SYSTEM 381
TRANSMISSION CONTROL SYSTEM 382
TRANSMISSION CONTROL SYSTEM DIAGRAM 382
TRANSMISSION GEAR SHIFT CONTROL SYSTEM 384
ELECTRIC MODULATION FUNCTION SYSTEM DIAGRAM 384
ELECTRIC MODULATION FUNCTION 385
DISPLAY FUNCTION OF GEAR SHIFT 385
AUTOMATIC GEAR SHIFT FUNCTION 385
SHIFT HOLD FUNCTION 386
KICKDOWN FUNCTION 386
AUTOMATIC KICKDOWN FUNCTION 387
TORQUE CONVERTER LOCKUP FUNCTION 387
HUNTING PREVENTION FUNCTION 388
ADJUSTING FUNCTION OF TRANSMISSION INITIAL LEARNING AND ECMV CURRENT 388
SHIFT POINT CHANGING FUNCTION 388
4TH GEAR SPEED LIMITATION FUNCTION 389
TRANSMISSION PROTECTION FUNCTION 390
PROTECTION FUNCTION WHEN TRAVEL DIRECTION IS CHANGED 390
SHIFT DOWN PROTECTION FUNCTION 390
ENGINE OVERRUN PREVENTION FUNCTION 391
MAXIMUM SPEED LIMITATION FUNCTION 391
NEUTRALIZER FUNCTION 392
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION 393
TRANSMISSION CUT-OFF FUNCTION 395
COMPONENT PARTS OF POWER TRAIN SYSTEM 397
DRIVE SHAFT 397
TORQUE CONVERTER 400
LOCKUP CLUTCH ECMV 406
TRANSMISSION 409
TRANSMISSION CONTROL VALVE 425
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 427
TRANSFER 432
TORQUE CONVERTER REGULATOR VALVE 434
MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE 436
TRANSMISSION LUBRICATION RELIEF VALVE 440
POWER TRAIN OIL COOLER 441
AXLE 442
CONVENTIONAL DIFFERENTIAL 444
LIMITED SLIP DIFFERENTIAL 446
FINAL DRIVE 452
AJSS KNOB 454
COMBINATION SWITCH 455
SHIFT HOLD SWITCH 458
KICKDOWN SWITCH 459
WORK EQUIPMENT SYSTEM 460
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 460
WORK EQUIPMENT SYSTEM DIAGRAM 462
WORK EQUIPMENT CONTROL SYSTEM 464
WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE 464
WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION 465
WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM 466
WORK EQUIPMENT LEVER OPERATION FUNCTION 467
BUCKET PRIORITY CONTROL FUNCTION 467
BOOM STOP MODULATION FUNCTION 467
WORK EQUIPMENT NEUTRAL LOCK SYSTEM 469
WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM 469
FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM 469
REMOTE POSITIONER SYSTEM 471
REMOTE BUCKET POSITIONER SYSTEM DIAGRAM 471
FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM 471
REMOTE BOOM POSITIONER SYSTEM DIAGRAM 472
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM 472
BUCKET POSITIONER AND BOOM POSITIONER 476
STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER 476
AUTO-DIGGING SYSTEM 477
AUTO-DIGGING SYSTEM DIAGRAM 477
FUNCTION OF AUTO-DIGGING SYSTEM 477
ECSS 479
ECSS DIAGRAM 479
FUNCTION OF ECSS 479
OPERATION OF ECSS 479
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 481
WORK EQUIPMENT LOCK SOLENOID VALVE 481
PILOT CIRCUIT ACCUMULATOR 482
ECSS CIRCUIT ACCUMULATOR 483
WORK EQUIPMENT ELECTRIC LEVER 484
ELECTRIC MONO-LEVER 487
MULTIFUNCTION MONO-LEVER 491
STEERING SYSTEM 492
LAYOUT DRAWING OF STEERING SYSTEM 492
SECONDARY STEERING SYSTEM 494
SECONDARY STEERING SYSTEM DIAGRAM 494
FUNCTION OF SECONDARY STEERING SYSTEM 494
JOYSTICK STEERING SYSTEM 495
LAYOUT DRAWING OF JOYSTICK STEERING SYSTEM 495
FUNCTION OF JOYSTICK STEERING SYSTEM 495
JOYSTICK CONTROL FUNCTION 496
JOYSTICK NEUTRAL SAFETY FUNCTION 499
JOYSTICK NEUTRAL INTERLOCK FUNCTION 499
JOYSTICK SPEED SENSING STEERING FUNCTION 499
JOYSTICK Hi/Lo SELECTOR FUNCTION 500
AJSS 501
LAYOUT DRAWING OF AJSS 501
AJSS DIAGRAM 502
FUNCTION OF AJSS 503
NEUTRALIZER FUNCTION OF AJSS 504
NEUTRAL INTERLOCK FUNCTION OF AJSS 504
SPEED SENSING STEERING FUNCTION OF AJSS 505
TURN SIGNAL PILOT LAMP CONTROL FUNCTION OF AJSS 506
STEERING COLUMN 508
STRUCTURE OF STEERING COLUMN 508
COMPONENT PARTS OF STEERING SYSTEM 509
AJSS EPC VALVE 509
STEERING LOCK VALVE 510
ROTARY VALVE 511
ORBITROL VALVE 514
STOP VALVE 518
STEERING VALVE 519
DIVERTER VALVE 530
SECONDARY STEERING RELIEF VALVE 534
SECONDARY STEERING PUMP 536
JOYSTICK KNOB 537
BRAKE SYSTEM 538
LAYOUT DRAWING OF BRAKE SYSTEM 538
PARKING BRAKE CONTROL SYSTEM 541
PARKING BRAKE CONTROL SYSTEM DIAGRAM 541
OPERATION OF PARKING BRAKE CONTROL SYSTEM 541
COMPONENT PARTS OF BRAKE SYSTEM 543
CHARGE VALVE 543
PARKING BRAKE SOLENOID VALVE 548
PARKING BRAKE EMERGENCY RELEASE VALVE 550
BRAKE CIRCUIT ACCUMULATOR 551
BRAKE VALVE 552
SLACK ADJUSTER 556
BRAKE 558
PARKING BRAKE 560
AUTO-GREASING SYSTEM 562
LAYOUT DRAWING OF AUTO-GREASING SYSTEM 562
SPECIFICATIONS OF AUTO-GREASING SYSTEM 563
FUNCTION OF AUTO-GREASING SYSTEM 565
COMPONENT PARTS OF AUTO-GREASING SYSTEM 566
AUTO-GREASING PUMP 566
UNDERCARRIAGE AND FRAME 567
FRAME, AXLE MOUNT AND CENTER HINGE PIN 567
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 567
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 568
TIRE 569
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE 569
STRUCTURE OF RADIAL TIRE 569
FUNCTION OF RADIAL TIRE 570
STRUCTURE OF BIAS TIRE 570
FUNCTION OF BIAS TIRE 570
WORK EQUIPMENT 571
STRUCTURE OF WORK EQUIPMENT 571
STRUCTURE OF BUCKET 572
STRUCTURE OF WORK EQUIPMENT LUBRICATION 574
CAB AND ITS ATTACHMENTS 576
ROPS CAB 576
STRUCTURE OF ROPS CAB (MACHINE WITH KOMTRAX TERMINAL) 576
STRUCTURE OF ROPS CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 577
FUNCTION OF ROPS CAB 577
20 STANDARD VALUE TABLE 579
CONTENTS 580
ABBREVIATION LIST 581
STANDARD VALUE TABLE FOR ENGINE 587
STANDARD VALUE TABLE FOR ENGINE: WA500-8E0 587
STANDARD VALUE TABLE FOR MACHINE 590
STANDARD VALUE TABLE FOR MACHINE: WA500-8E0 590
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 611
30 TESTING AND ADJUSTING 615
CONTENTS 616
ABBREVIATION LIST 620
RELATED INFORMATION ON TESTING AND ADJUSTING 626
TOOLS FOR TESTING AND ADJUSTING 626
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 636
ENGINE AND COOLING SYSTEM 637
TEST ENGINE SPEED 637
METHOD FOR TESTING ENGINE SPEED 637
TEST BOOST PRESSURE 644
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 644
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL 645
TESTING EXHAUST GAS TEMPERATURE 648
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 648
TEST EXHAUST GAS COLOR 650
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 650
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 651
TEST AND ADJUST VALVE CLEARANCE 653
METHOD FOR TESTING VALVE CLEARANCE 653
METHOD FOR ADJUSTING VALVE CLEARANCE 654
TEST COMPRESSION PRESSURE 655
METHOD FOR TESTING COMPRESSION PRESSURE 655
TEST BLOWBY PRESSURE 658
METHOD FOR TESTING BLOWBY PRESSURE 658
TEST ENGINE OIL PRESSURE 661
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 661
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 661
TEST EGR VALVE AND VGT OIL PRESSURE 663
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 663
TEST FUEL PRESSURE 665
METHOD FOR TESTING FUEL PRESSURE 665
TEST FUEL RETURN RATE AND LEAKAGE 667
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 668
BLEEDING AIR FROM FUEL SYSTEM 671
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 672
TEST FUEL CIRCUIT FOR LEAKAGE 673
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 673
HANDLE CYLINDER CUT-OUT MODE OPERATION 675
HANDLE NO-INJECTION CRANKING OPERATION 676
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 677
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 677
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 678
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 678
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 679
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 679
CLEAN FUEL DOSER 680
METHOD FOR CLEANING FUEL DOSER 680
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 683
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 683
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 690
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 690
TEST SCR RELATED FUNCTIONS 691
TEST AdBlue/DEF PUMP RAISED PRESSURE 695
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 698
TEST AdBlue/DEF LINE HEATER RELAY 1 703
TEST AdBlue/DEF LINE HEATER RELAY 2 707
TEST AdBlue/DEF PUMP HEATER RELAY 711
TEST AdBlue/DEF TANK HEATER VALVE 715
TEST SCR NOx REMOVAL EFFICIENCY 719
CLEAN AdBlue/DEF TANK 723
METHOD FOR CLEANING AdBlue/DEF TANK 723
POWER TRAIN 727
TEST AND ADJUST POWER TRAIN OIL PRESSURE 727
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 729
METHOD FOR ADJUSTING POWER TRAIN OIL PRESSURE 744
ADJUST TRANSMISSION INPUT SPEED SENSOR 745
METHOD FOR ADJUSTING TRANSMISSION INPUT SPEED SENSOR 745
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 747
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR 747
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 749
METHOD FOR FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 749
MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 751
METHOD FOR MOVING DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 752
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 753
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 753
STEERING SYSTEM 754
TEST STEERING WHEEL 754
METHOD FOR TESTING STEERING WHEEL 754
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 756
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE 756
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 761
BLEED AIR FROM STEERING CYLINDER CIRCUIT 762
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT 762
TEST AND ADJUST STEERING STOP VALVE 763
METHOD FOR TESTING STEERING STOP VALVE 763
METHOD FOR ADJUSTING STEERING STOP VALVE 763
BRAKE SYSTEM 765
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 765
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 765
TEST WHEEL BRAKE OIL PRESSURE 766
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE 766
TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE 768
METHOD FOR TESTING BRAKE ACCUMULATOR CHARGE PRESSURE 768
METHOD FOR ADJUSTING BRAKE ACCUMULATOR CHARGE PRESSURE 769
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 770
TEST ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 770
CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 773
BLEED AIR FROM BRAKE CIRCUIT 779
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT 779
TEST BRAKING PERFORMANCE 782
METHOD FOR TESTING BRAKING PERFORMANCE 782
TEST BRAKE PEDAL 783
METHOD FOR TESTING BRAKE PEDAL 783
TEST AND ADJUST BRAKE PEDAL AND LINKAGE 784
METHOD FOR TESTING BRAKE PEDAL AND LINKAGE 784
METHOD FOR ADJUSTING BRAKE PEDAL AND LINKAGE 784
ADJUST LEFT BRAKE PEDAL OPERATION SWITCH 785
METHOD FOR ADJUSTING LEFT BRAKE PEDAL OPERATION SWITCH 785
TEST LOWERING OF WHEEL BRAKE PRESSURE 786
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE 787
TEST WEAR OF WHEEL BRAKE DISC 789
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC 789
TEST PARKING BRAKE OIL PRESSURE 791
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE 791
TEST PARKING BRAKE PERFORMANCE 793
METHOD FOR TESTING PARKING BRAKE PERFORMANCE 793
RELEASE PARKING BRAKE MANUALLY 794
METHOD FOR RELEASING PARKING BRAKE WITH SECONDARY PARKING BRAKE RELEASE VALVE 794
METHOD FOR RELEASING PARKING BRAKE WITH BOLT 795
TEST WEAR AMOUNT OF PARKING BRAKE DISC 797
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC 797
HYDRAULIC SYSTEM 799
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 799
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 799
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE 801
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE 801
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE 806
TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE 807
METHOD FOR TESTING WORK EQUIPMENT EPC OIL PRESSURE 807
METHOD FOR ADJUSTING WORK EQUIPMENT EPC OIL PRESSURE 809
BLEED AIR FROM WORK EQUIPMENT CIRCUIT 810
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 810
TEST COOLING FAN SPEED 812
METHOD FOR TESTING COOLING FAN SPEED 812
TEST COOLING FAN CIRCUIT OIL PRESSURE 813
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 813
BLEED AIR FROM COOLING FAN CIRCUIT 817
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT 817
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS 819
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE 820
CHARGE ECSS ACCUMULATOR WITH NITROGEN GAS 825
WORK EQUIPMENT 833
TEST AND ADJUST BUCKET POTENTIOMETER LEVER 833
METHOD FOR TESTING BUCKET POTENTIOMETER LEVER 833
METHOD FOR ADJUSTING BUCKET POTENTIOMETER LEVER 833
TEST AND ADJUST BOOM POTENTIOMETER LEVER 835
METHOD FOR TESTING BOOM POTENTIOMETER LEVER 835
METHOD FOR ADJUSTING BOOM POTENTIOMETER LEVER 835
CAB AND ITS ATTACHMENTS 836
TEST DIRECTIONAL LEVER 836
METHOD FOR TESTING DIRECTIONAL LEVER 836
TEST WORK EQUIPMENT CONTROL LEVER 837
METHOD FOR TESTING WORK EQUIPMENT CONTROL LEVER 837
TEST MULTIFUNCTION MONO-LEVER 838
METHOD FOR TESTING MULTIFUNCTION MONO-LEVER 838
TEST AJSS LEVER (FOR AJSS SPEC) 840
METHOD FOR TESTING AJSS LEVER 840
TEST STEERING LOCK LEVER(FOR AJSS SPEC) 843
METHOD FOR TESTING OF STEERING LOCK LEVER 843
TEST AND ADJUST AJSS LEVER/FRAME ANGLE SENSOR (FOR AJSS SPEC) 844
METHOD FOR TESTING AJSS LEVER/FRAME ANGLE SENSOR 844
METHOD FOR ADJUSTING AJSS LEVER/FRAME ANGLE SENSOR 844
TEST AND AJUST STEERING STOPPER BOLT (FOR AJSS SPEC) 846
METHOD FOR TESTING STEERING STOPPER VALVE 846
METHOD FOR ADJUSTING STEERING STOPPER VALVE 846
ADJUST RATTLING OPERATOR’S SEAT 848
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 848
ELECTRICAL SYSTEM 849
SET AND ADJUST EACH EQUIPMENT 849
SET AND OPERATE MACHINE MONITOR 854
OPERATOR MODE 858
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 858
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 858
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 859
CHECKING FUNCTION OF SERVICE METER AND ODOMETER 860
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 860
SERVICE MODE 864
METHOD FOR OPERATING SERVICE MODE 864
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 867
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 880
ABNORMALITY RECORD MENU 896
METHOD FOR CONFIRMING MAINTENANCE RECORD 901
METHOD FOR OPERATING MAINTENANCE MODE SETTING 903
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 908
DEFAULT MENU 910
DIAGNOSTIC TESTS MENU 926
ADJUSTMENT MENU 938
METHOD FOR PERFORMING NO-INJECTION CRANKING 986
KOMTRAX SETTINGS MENU 988
METHOD FOR DISPLAYING SERVICE MESSAGE 993
START UP KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) 995
STOP USING OF KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) 999
START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1001
STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1007
ADJUST REARVIEW CAMERA ANGLE 1009
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 1009
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 1010
HANDLE BATTERY DISCONNECT SWITCH (MACHINE WITH KOMTRAX TERMINAL) 1011
HANDLE BATTERY DISCONNECT SWITCH (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1012
TEST DIODES 1013
METHOD FOR TESTING DIODE USING DIGITAL TESTER 1013
METHOD FOR TESTING DIODE USING ANALOG TESTER 1013
AUTO-GREASING DEVICE 1014
BLEED THE AIR OF AUTO-GREASING SYSTEM 1014
METHOD FOR BLEEDING THE AIR OF AUTO-GREASING SYSTEM 1014
CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 1017
METHOD FOR CHANGING THE LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 1018
Pm CLINIC 1020
Pm CLINIC SERVICE 1020
Pm CLINIC CHECK SHEET: WA500-8E0 1023
40 TROUBLESHOOTING 1033
CONTENTS 1034
ABBREVIATION LIST 1048
RELATED INFORMATION ON TROUBLESHOOTING 1054
GENERAL TROUBLESHOOTING POINTS 1054
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 1055
SEQUENCE OF EVENTS IN TROUBLESHOOTING 1067
CHECKS BEFORE TROUBLESHOOTING 1069
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 1071
WALK-AROUND CHECK 1071
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 1073
CHECK FUEL LEVEL AND TYPE 1073
CHECK IMPURE INGREDIENT IN FUEL 1073
CHECK AdBule/DEF LEVEL AND TYPE 1074
CHECK FUEL PREFILTER 1074
CHECK MAIN FILTER 1076
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 1077
CHECK COOLANT LEVEL (RESERVOIR TANK) 1078
CHECK CLOGGING OF AIR CLEANER 1079
OUTER ELEMENT – CLEAN 1079
REPLACE INNER ELEMENT 1082
CHECK HYDRAULIC OIL LEVEL 1084
CHECK HYDRAULIC OIL STRAINER 1084
CHECK HYDRAULIC FILTER 1087
CHECK OIL LEVEL IN TRANSMISSION CASE 1090
CHECK OIL LEVEL IN FRONT AXLE CASE 1092
CHECK OIL LEVEL IN REAR AXLE CASE 1092
BLEED AIR FROM FUEL SYSTEM 1093
BLEED AIR FROM HYDRAULIC SYSTEM 1093
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 1093
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 1099
PROCEDURE FOR TESTING AND TROUBLESHOOTING 1112
SYMPTOM AND TROUBLESHOOTING NUMBERS 1114
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1119
CONNECTOR LIST AND LAYOUT (MACHINE WITH KOMTRAX TERMINAL) 1121
CONNECTOR LIST AND LAYOUT (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1149
CONNECTOR CONTACT IDENTIFICATION 1177
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1217
FUSE LOCATION TABLE(MACHINE WITH KOMTRAX TERMINAL) 1223
FUSE LOCATION TABLE(MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1227
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1231
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 1235
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 1237
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 1243
FAILURE CODES TABLE 1245
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1269
FAILURE CODE [1500L0] 1269
FAILURE CODE [15B0NX] 1270
FAILURE CODE [15SAL1] 1272
FAILURE CODE [15SALH] 1274
FAILURE CODE [15SBL1] 1276
FAILURE CODE [15SBLH] 1278
FAILURE CODE [15SEL1] 1280
FAILURE CODE [15SELH] 1282
FAILURE CODE [15SFL1] 1284
FAILURE CODE [15SFLH] 1286
FAILURE CODE [15SGL1] 1288
FAILURE CODE [15SGLH] 1290
FAILURE CODE [15SHL1] 1292
FAILURE CODE [15SHLH] 1294
FAILURE CODE [2F00MA] 1297
FAILURE CODE [2F00MB] 1301
FAILURE CODE [2G42ZG] 1304
FAILURE CODE [2G43ZG] 1306
FAILURE CODE [879AKA] 1308
FAILURE CODE [879AKB] 1310
FAILURE CODE [879BKA] 1312
FAILURE CODE [879BKB] 1314
FAILURE CODE [879CKA] 1316
FAILURE CODE [879CKB] 1318
FAILURE CODE [879DKZ] 1320
FAILURE CODE [879EMC] 1322
FAILURE CODE [879FMC] 1325
FAILURE CODE [989A00] 1328
FAILURE CODE [989L00] 1329
FAILURE CODE [989M00] 1330
FAILURE CODE [989N00] 1331
FAILURE CODE [A1U0N3] 1332
FAILURE CODE [A1U0N4] 1334
FAILURE CODE [AA10NX] 1336
FAILURE CODE [AB00KE] 1338
FAILURE CODE [AB00KY] 1340
FAILURE CODE [AQ10N3] 1342
FAILURE CODE [AS00N3] 1344
FAILURE CODE [AS00R2] 1346
FAILURE CODE [AS00R3] 1347
FAILURE CODE [AS00R4] 1348
FAILURE CODE [AS00R5] 1349
FAILURE CODE [AS00R6] 1350
FAILURE CODE [AS00ZK] 1351
FAILURE CODE [AS10KM] 1352
FAILURE CODE [AS10NR] 1353
FAILURE CODE [AS10NT] 1354
FAILURE CODE [B@BAZG] 1355
FAILURE CODE [B@BCNS] 1356
FAILURE CODE [B@BCQA] 1357
FAILURE CODE [B@BCZK] 1359
FAILURE CODE [B@C7NS] 1361
FAILURE CODE [B@CENS] 1363
FAILURE CODE [B@HANS] 1364
FAILURE CODE [CA115] 1365
FAILURE CODE [CA122] 1369
FAILURE CODE [CA123] 1371
FAILURE CODE [CA131] 1373
FAILURE CODE [CA132] 1375
FAILURE CODE [CA135] 1377
FAILURE CODE [CA141] 1379
FAILURE CODE [CA144] 1381
FAILURE CODE [CA145] 1383
FAILURE CODE [CA153] 1385
FAILURE CODE [CA154] 1388
FAILURE CODE [CA187] 1390
FAILURE CODE [CA221] 1392
FAILURE CODE [CA222] 1394
FAILURE CODE [CA227] 1396
FAILURE CODE [CA234] 1398
FAILURE CODE [CA238] 1399
FAILURE CODE [CA239] 1400
FAILURE CODE [CA249] 1401
FAILURE CODE [CA256] 1403
FAILURE CODE [CA271] 1405
FAILURE CODE [CA272] 1407
FAILURE CODE [CA273] 1408
FAILURE CODE [CA274] 1410
FAILURE CODE [CA322] 1411
FAILURE CODE [CA323] 1413
FAILURE CODE [CA324] 1415
FAILURE CODE [CA325] 1417
FAILURE CODE [CA331] 1419
FAILURE CODE [CA332] 1421
FAILURE CODE [CA343] 1423
FAILURE CODE [CA351] 1425
FAILURE CODE [CA352] 1427
FAILURE CODE [CA356] 1429
FAILURE CODE [CA357] 1431
FAILURE CODE [CA386] 1433
FAILURE CODE [CA431] 1435
FAILURE CODE [CA432] 1438
FAILURE CODE [CA441] 1442
FAILURE CODE [CA442] 1444
FAILURE CODE [CA449] 1446
FAILURE CODE [CA451] 1447
FAILURE CODE [CA452] 1449
FAILURE CODE [CA515] 1451
FAILURE CODE [CA516] 1453
FAILURE CODE [CA553] 1455
FAILURE CODE [CA555] 1456
FAILURE CODE [CA556] 1458
FAILURE CODE [CA559] 1460
FAILURE CODE [CA595] 1465
FAILURE CODE [CA687] 1467
FAILURE CODE [CA689] 1469
FAILURE CODE [CA691] 1471
FAILURE CODE [CA692] 1473
FAILURE CODE [CA697] 1475
FAILURE CODE [CA698] 1476
FAILURE CODE [CA731] 1477
FAILURE CODE [CA778] 1481
FAILURE CODE [CA1117] 1483
FAILURE CODE [CA1664] 1485
FAILURE CODE [CA1669] 1488
FAILURE CODE [CA1673] 1489
FAILURE CODE [CA1677] 1490
FAILURE CODE [CA1678] 1491
FAILURE CODE [CA1682] 1492
FAILURE CODE [CA1683] 1496
FAILURE CODE [CA1684] 1498
FAILURE CODE [CA1686] 1500
FAILURE CODE [CA1691] 1501
FAILURE CODE [CA1694] 1503
FAILURE CODE [CA1695] 1505
FAILURE CODE [CA1696] 1507
FAILURE CODE [CA1712] 1509
FAILURE CODE [CA1713] 1512
FAILURE CODE [CA1714] 1515
FAILURE CODE [CA1715] 1516
FAILURE CODE [CA1776] 1517
FAILURE CODE [CA1777] 1520
FAILURE CODE [CA1843] 1523
FAILURE CODE [CA1844] 1525
FAILURE CODE [CA1879] 1527
FAILURE CODE [CA1881] 1529
FAILURE CODE [CA1883] 1531
FAILURE CODE [CA1885] 1534
FAILURE CODE [CA1887] 1536
FAILURE CODE [CA1921] 1538
FAILURE CODE [CA1922] 1541
FAILURE CODE [CA1923] 1546
FAILURE CODE [CA1924] 1548
FAILURE CODE [CA1925] 1550
FAILURE CODE [CA1927] 1552
FAILURE CODE [CA1928] 1554
FAILURE CODE [CA1942] 1556
FAILURE CODE [CA1963] 1558
FAILURE CODE [CA1977] 1562
FAILURE CODE [CA1993] 1564
FAILURE CODE [CA2185] 1567
FAILURE CODE [CA2186] 1569
FAILURE CODE [CA2249] 1571
FAILURE CODE [CA2265] 1576
FAILURE CODE [CA2266] 1578
FAILURE CODE [CA2271] 1580
FAILURE CODE [CA2272] 1582
FAILURE CODE [CA2349] 1584
FAILURE CODE [CA2353] 1586
FAILURE CODE [CA2357] 1588
FAILURE CODE [CA2381] 1590
FAILURE CODE [CA2382] 1592
FAILURE CODE [CA2383] 1594
FAILURE CODE [CA2386] 1596
FAILURE CODE [CA2387] 1598
FAILURE CODE [CA2555] 1600
FAILURE CODE [CA2556] 1602
FAILURE CODE [CA2637] 1604
FAILURE CODE [CA2639] 1606
FAILURE CODE [CA2732] 1608
FAILURE CODE [CA2733] 1610
FAILURE CODE [CA2741] 1612
FAILURE CODE [CA2765] 1613
FAILURE CODE [CA2771] 1614
FAILURE CODE [CA2777] 1620
FAILURE CODE [CA2878] 1623
FAILURE CODE [CA2881] 1626
FAILURE CODE [CA2976] 1629
FAILURE CODE [CA3133] 1631
FAILURE CODE [CA3134] 1633
FAILURE CODE [CA3135] 1635
FAILURE CODE [CA3142] 1638
FAILURE CODE [CA3143] 1639
FAILURE CODE [CA3144] 1640
FAILURE CODE [CA3146] 1643
FAILURE CODE [CA3147] 1644
FAILURE CODE [CA3148] 1645
FAILURE CODE [CA3151] 1648
FAILURE CODE [CA3165] 1653
FAILURE CODE [CA3167] 1656
FAILURE CODE [CA3229] 1660
FAILURE CODE [CA3231] 1663
FAILURE CODE [CA3232] 1666
FAILURE CODE [CA3235] 1671
FAILURE CODE [CA3239] 1673
FAILURE CODE [CA3241] 1676
FAILURE CODE [CA3242] 1679
FAILURE CODE [CA3251] 1682
FAILURE CODE [CA3253] 1685
FAILURE CODE [CA3254] 1690
FAILURE CODE [CA3255] 1694
FAILURE CODE [CA3256] 1697
FAILURE CODE [CA3311] 1700
FAILURE CODE [CA3312] 1703
FAILURE CODE [CA3313] 1706
FAILURE CODE [CA3314] 1707
FAILURE CODE [CA3315] 1708
FAILURE CODE [CA3316] 1712
FAILURE CODE [CA3317] 1713
FAILURE CODE [CA3318] 1714
FAILURE CODE [CA3319] 1718
FAILURE CODE [CA3321] 1719
FAILURE CODE [CA3322] 1720
FAILURE CODE [CA3419] 1724
FAILURE CODE [CA3421] 1726
FAILURE CODE [CA3497] 1728
FAILURE CODE [CA3498] 1729
FAILURE CODE [CA3543] 1730
FAILURE CODE [CA3545] 1735
FAILURE CODE [CA3547] 1737
FAILURE CODE [CA3558] 1738
FAILURE CODE [CA3559] 1740
FAILURE CODE [CA3562] 1742
FAILURE CODE [CA3563] 1744
FAILURE CODE [CA3567] 1747
FAILURE CODE [CA3568] 1751
FAILURE CODE [CA3571] 1757
FAILURE CODE [CA3572] 1759
FAILURE CODE [CA3574] 1761
FAILURE CODE [CA3575] 1764
FAILURE CODE [CA3577] 1766
FAILURE CODE [CA3578] 1768
FAILURE CODE [CA3582] 1770
FAILURE CODE [CA3583] 1777
FAILURE CODE [CA3596] 1779
FAILURE CODE [CA3649] 1783
FAILURE CODE [CA3681] 1786
FAILURE CODE [CA3682] 1791
FAILURE CODE [CA3713] 1797
FAILURE CODE [CA3717] 1800
FAILURE CODE [CA3718] 1801
FAILURE CODE [CA3725] 1802
FAILURE CODE [CA3748] 1805
FAILURE CODE [CA3751] 1808
FAILURE CODE [CA3755] 1810
FAILURE CODE [CA3866] 1812
FAILURE CODE [CA3867] 1816
FAILURE CODE [CA3868] 1819
FAILURE CODE [CA3899] 1823
FAILURE CODE [CA3911] 1825
FAILURE CODE [CA3912] 1829
FAILURE CODE [CA3932] 1831
FAILURE CODE [CA3933] 1833
FAILURE CODE [CA3934] 1835
FAILURE CODE [CA3935] 1838
FAILURE CODE [CA3936] 1840
FAILURE CODE [CA4151] 1842
FAILURE CODE [CA4152] 1846
FAILURE CODE [CA4155] 1850
FAILURE CODE [CA4156] 1852
FAILURE CODE [CA4157] 1855
FAILURE CODE [CA4158] 1857
FAILURE CODE [CA4159] 1858
FAILURE CODE [CA4161] 1859
FAILURE CODE [CA4162] 1862
FAILURE CODE [CA4163] 1865
FAILURE CODE [CA4164] 1867
FAILURE CODE [CA4165] 1870
FAILURE CODE [CA4166] 1873
FAILURE CODE [CA4168] 1875
FAILURE CODE [CA4169] 1880
FAILURE CODE [CA4171] 1885
FAILURE CODE [CA4249] 1890
FAILURE CODE [CA4251] 1895
FAILURE CODE [CA4259] 1900
FAILURE CODE [CA4261] 1904
FAILURE CODE [CA4277] 1907
FAILURE CODE [CA4281] 1910
FAILURE CODE [CA4459] 1914
FAILURE CODE [CA4461] 1916
FAILURE CODE [CA4658] 1919
FAILURE CODE [CA4731] 1923
FAILURE CODE [CA4732] 1924
FAILURE CODE [CA4739] 1925
FAILURE CODE [CA4768] 1926
FAILURE CODE [CA4769] 1928
FAILURE CODE [CA4842] 1931
FAILURE CODE [CA4952] (MACHINE WITH KOMTRAX TERMINAL) 1934
FAILURE CODE [CA4952] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1936
FAILURE CODE [CA5115] 1938
FAILURE CODE [CA5179] 1941
FAILURE CODE [CA5181] 1943
FAILURE CODE [CA5383] 1945
FAILURE CODE [D160KA] 1947
FAILURE CODE [D160KB] 1949
FAILURE CODE [D160KY] 1951
FAILURE CODE [D191KA] 1953
FAILURE CODE [D191KB] 1956
FAILURE CODE [D191KY] 1959
FAILURE CODE [D192KA] 1961
FAILURE CODE [D192KB] 1963
FAILURE CODE [D192KY] 1965
FAILURE CODE [D193KA] 1966
FAILURE CODE [D193KB] 1968
FAILURE CODE [D193KY] 1970
FAILURE CODE [D193MC] 1972
FAILURE CODE [D19JKZ] 1974
FAILURE CODE [D1E6KA] 1976
FAILURE CODE [D1E6KB] 1978
FAILURE CODE [D1E6KY] 1980
FAILURE CODE [D5ZHKA] 1982
FAILURE CODE [D5ZHKB] 1984
FAILURE CODE [D5ZHKZ] 1986
FAILURE CODE [D5ZHL6] 1989
FAILURE CODE [D5ZMLD] 1991
FAILURE CODE [D811MC] (MACHINE WITH KOMTRAX TERMINAL) 1993
FAILURE CODE [D811MC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1994
FAILURE CODE [D862KA] (MACHINE WITH KOMTRAX TERMINAL) 1995
FAILURE CODE [D862KA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1996
FAILURE CODE [D8ALKA] (MACHINE WITH KOMTRAX TERMINAL) 1997
FAILURE CODE [D8ALKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1999
FAILURE CODE [D8ALKB] (MACHINE WITH KOMTRAX TERMINAL) 2001
FAILURE CODE [D8ALKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2003
FAILURE CODE [D8AQK4] (MACHINE WITH KOMTRAX TERMINAL) 2005
FAILURE CODE [D8AQK4] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2006
FAILURE CODE [D8AQKR] (MACHINE WITH KOMTRAX TERMINAL) 2007
FAILURE CODE [D8AQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2009
FAILURE CODE [D8G1KT] 2011
FAILURE CODE [D8G6KT] 2012
FAILURE CODE [DAF0KT] 2013
FAILURE CODE [DAF0MB] 2014
FAILURE CODE [DAF0MC] 2015
FAILURE CODE [DAF3KK] 2016
FAILURE CODE [DAF8KB] 2018
FAILURE CODE [DAFDKB] 2020
FAILURE CODE [DAFGMC] (MACHINE WITH KOMTRAX TERMINAL) 2022
FAILURE CODE [DAFGMC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2023
FAILURE CODE [DAFLKA] (MACHINE WITH KOMTRAX TERMINAL) 2024
FAILURE CODE [DAFLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2026
FAILURE CODE [DAFLKB] (MACHINE WITH KOMTRAX TERMINAL) 2028
FAILURE CODE [DAFLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2030
FAILURE CODE [DAFQKR] (MACHINE WITH KOMTRAX TERMINAL) 2032
FAILURE CODE [DAFQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2033
FAILURE CODE [DAQ0KK] 2034
FAILURE CODE [DAQ0KT] 2037
FAILURE CODE [DAQ0MC] 2038
FAILURE CODE [DAQ1KA] 2039
FAILURE CODE [DAQ2KK] 2042
FAILURE CODE [DAQ4KB] 2045
FAILURE CODE [DAQ9KQ] 2047
FAILURE CODE [DAQLKA] (MACHINE WITH KOMTRAX TERMINAL) 2048
FAILURE CODE [DAQLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2050
FAILURE CODE [DAQLKB] (MACHINE WITH KOMTRAX TERMINAL) 2052
FAILURE CODE [DAQLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2054
FAILURE CODE [DAQQKR] 2056
FAILURE CODE [DAQRKR] 2057
FAILURE CODE [DAQRMA] 2058
FAILURE CODE [DAZ9KQ] 2059
FAILURE CODE [DAZQKR] 2060
FAILURE CODE [DB2QKR] (MACHINE WITH KOMTRAX TERMINAL) 2061
FAILURE CODE [DB2QKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2066
FAILURE CODE [DB2RKR] 2071
FAILURE CODE [DB90KK] 2077
FAILURE CODE [DB90KT] 2080
FAILURE CODE [DB90MC] 2081
FAILURE CODE [DB91KA] 2082
FAILURE CODE [DB92KK] 2085
FAILURE CODE [DB95KX] 2088
FAILURE CODE [DB96KX] 2091
FAILURE CODE [DB99KQ] 2093
FAILURE CODE [DB9LKA] (MACHINE WITH KOMTRAX TERMINAL) 2094
FAILURE CODE [DB9LKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2096
FAILURE CODE [DB9LKB] (MACHINE WITH KOMTRAX TERMINAL) 2098
FAILURE CODE [DB9LKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2100
FAILURE CODE [DB9QKR] 2102
FAILURE CODE [DB9RKR] 2103
FAILURE CODE [DB9RMA] 2104
FAILURE CODE [DBE5KX] 2105
FAILURE CODE [DBE6KX] 2107
FAILURE CODE [DD1ALD] 2109
FAILURE CODE [DDA8KY] 2111
FAILURE CODE [DDA9KY] 2113
FAILURE CODE [DDAAL6] 2115
FAILURE CODE [DDAAL6] 2117
FAILURE CODE [DDB6L4] 2120
FAILURE CODE [DDD1LD] 2123
FAILURE CODE [DDE5KA] 2125
FAILURE CODE [DDK3KA] 2127
FAILURE CODE [DDK3KB] 2130
FAILURE CODE [DDK4KA] 2133
FAILURE CODE [DDK4KB] 2136
FAILURE CODE [DDK5L4] 2138
FAILURE CODE [DDK6KA] 2140
FAILURE CODE [DDK6KB] 2143
FAILURE CODE [DDKLKA] 2146
FAILURE CODE [DDKLKB] 2148
FAILURE CODE [DDNRKY] 2150
FAILURE CODE [DDP5KA] 2152
FAILURE CODE [DDT0L4] 2154
FAILURE CODE [DDT4LD] 2156
FAILURE CODE [DDT9LD] 2158
FAILURE CODE [DDTALD] 2160
FAILURE CODE [DDW9LD] 2162
FAILURE CODE [DDWLLD] 2164
FAILURE CODE [DF10KA] 2166
FAILURE CODE [DF10KB] 2169
FAILURE CODE [DGF1KA] 2172
FAILURE CODE [DGF1KB] 2174
FAILURE CODE [DGH2KX] 2176
FAILURE CODE [DGR2KB] 2178
FAILURE CODE [DGR2KZ] 2180
FAILURE CODE [DGT1KA] 2182
FAILURE CODE [DGT1KB] 2184
FAILURE CODE [DH21KA] 2186
FAILURE CODE [DH21KB] 2189
FAILURE CODE [DHA4KA] 2191
FAILURE CODE [DHAAMA] 2193
FAILURE CODE [DHACMA] 2195
FAILURE CODE [DHPCKX] 2197
FAILURE CODE [DHPDKX] 2200
FAILURE CODE [DHQ2KX] 2203
FAILURE CODE [DHT1KX] 2205
FAILURE CODE [DHT2L6] 2208
FAILURE CODE [DHT5KX] 2210
FAILURE CODE [DHT7KX] 2213
FAILURE CODE [DHT8KA] 2216
FAILURE CODE [DHT8KB] 2219
FAILURE CODE [DHT8ZG] 2221
FAILURE CODE [DJF1KA] 2222
FAILURE CODE [DK30KA] 2224
FAILURE CODE [DK30KY] 2226
FAILURE CODE [DK55KA] 2228
FAILURE CODE [DK55KY] 2231
FAILURE CODE [DK55L5] 2233
FAILURE CODE [DK59KA] 2234
FAILURE CODE [DK59KY] 2238
FAILURE CODE [DK59L8] 2242
FAILURE CODE [DK5AKA] 2247
FAILURE CODE [DK5AKY] 2251
FAILURE CODE [DK5BKA] 2255
FAILURE CODE [DK5BKY] 2259
FAILURE CODE [DK5BL8] 2263
FAILURE CODE [DK5CKA] 2268
FAILURE CODE [DK5CKY] 2272
FAILURE CODE [DK5DKA] 2276
FAILURE CODE [DK5DKY] 2279
FAILURE CODE [DK5DL8] 2282
FAILURE CODE [DK5EKA] 2287
FAILURE CODE [DK5EKY] 2290
FAILURE CODE [DK5FKA] 2293
FAILURE CODE [DK5FKY] 2296
FAILURE CODE [DK5FL8] 2299
FAILURE CODE [DK5GKA] 2303
FAILURE CODE [DK5GKY] 2306
FAILURE CODE [DKA0KA] 2309
FAILURE CODE [DKA0KY] 2312
FAILURE CODE [DKA0L0] 2315
FAILURE CODE [DKA1KA] 2318
FAILURE CODE [DKA1KY] 2321
FAILURE CODE [DKD0KA] 2324
FAILURE CODE [DKD0KY] 2326
FAILURE CODE [DKD0L8] 2328
FAILURE CODE [DLF1KA] 2329
FAILURE CODE [DLF1LC] 2331
FAILURE CODE [DLM3KA] 2333
FAILURE CODE [DLM3LC] 2335
FAILURE CODE [DLT3KA] 2337
FAILURE CODE [DLT3LC] 2339
FAILURE CODE [DPQ1KR] 2341
FAILURE CODE [DPQ2KR] 2344
FAILURE CODE [DPQ3KR] 2347
FAILURE CODE [DSJ0KR] 2351
FAILURE CODE [DT20KB] 2355
FAILURE CODE [DT22KB] 2357
FAILURE CODE [DT23KB] 2359
FAILURE CODE [DV00KB] 2361
FAILURE CODE [DW2BKA] 2363
FAILURE CODE [DW2BKB] 2364
FAILURE CODE [DW2BKY] 2365
FAILURE CODE [DW2BL1] 2366
FAILURE CODE [DW2BLH] 2368
FAILURE CODE [DW4PKA] 2370
FAILURE CODE [DW4PKB] 2372
FAILURE CODE [DW4PKY] 2374
FAILURE CODE [DW4QKA] 2376
FAILURE CODE [DW4QKB] 2378
FAILURE CODE [DW4QKY] 2380
FAILURE CODE [DW4RKA] 2382
FAILURE CODE [DW4RKB] 2384
FAILURE CODE [DW4RKY] 2386
FAILURE CODE [DW4SKA] 2388
FAILURE CODE [DW4SKB] 2390
FAILURE CODE [DW4SKY] 2392
FAILURE CODE [DW7BKA] 2394
FAILURE CODE [DW7BKB] 2396
FAILURE CODE [DW7BKY] 2398
FAILURE CODE [DWM1KA] 2399
FAILURE CODE [DWM1KB] 2401
FAILURE CODE [DWM1KY] 2403
FAILURE CODE [DWN6KA] 2405
FAILURE CODE [DWN6KB] 2407
FAILURE CODE [DWN6KY] 2409
FAILURE CODE [DWN8KA] 2411
FAILURE CODE [DWN8KB] 2413
FAILURE CODE [DWN8KY] 2415
FAILURE CODE [DX16KA] 2417
FAILURE CODE [DX16KB] 2419
FAILURE CODE [DX16KY] 2421
FAILURE CODE [DXA1KA] 2423
FAILURE CODE [DXA1KB] 2425
FAILURE CODE [DXA1KY] 2427
FAILURE CODE [DXF0KA] 2429
FAILURE CODE [DXF0KB] 2431
FAILURE CODE [DXF0KY] 2433
FAILURE CODE [DXH1KA] 2435
FAILURE CODE [DXH1KB] 2437
FAILURE CODE [DXH1KY] 2439
FAILURE CODE [DXH4KA] 2441
FAILURE CODE [DXH4KB] 2443
FAILURE CODE [DXH4KY] 2445
FAILURE CODE [DXH5KA] 2447
FAILURE CODE [DXH5KB] 2449
FAILURE CODE [DXH5KY] 2451
FAILURE CODE [DXH6KA] 2453
FAILURE CODE [DXH6KB] 2455
FAILURE CODE [DXH6KY] 2457
FAILURE CODE [DXH7KA] 2459
FAILURE CODE [DXH7KB] 2461
FAILURE CODE [DXH7KY] 2463
FAILURE CODE [DXH8KA] 2465
FAILURE CODE [DXH8KB] 2467
FAILURE CODE [DXH8KY] 2469
FAILURE CODE [DXHHKA] 2471
FAILURE CODE [DXHHKB] 2473
FAILURE CODE [DXHHKY] 2475
FAILURE CODE [DXHJKA] 2477
FAILURE CODE [DXHJKB] 2479
FAILURE CODE [DXHJKY] 2481
FAILURE CODE [DXHKKA] 2483
FAILURE CODE [DXHKKB] 2485
FAILURE CODE [DXHKKY] 2487
FAILURE CODE [DXHLKA] 2489
FAILURE CODE [DXHLKB] 2491
FAILURE CODE [DXHLKY] 2493
FAILURE CODE [DXHMKA] 2495
FAILURE CODE [DXHMKB] 2497
FAILURE CODE [DXHMKY] 2499
FAILURE CODE [F313KA] 2501
FAILURE CODE [F313KB] 2503
FAILURE CODE [F318KB] 2504
FAILURE CODE [F318KY] 2506
FAILURE CODE [LA00L3] 2507
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2508
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2508
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 2517
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2520
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2523
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING 2525
E-6 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING (FOR MACHINES EQUIPPED WITH EMERGENCY ENGINE STOP SWITCH) 2528
E-7 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING 2531
E-8 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS) 2534
E-9 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY 2537
E-10 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 2540
E-11 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 2543
E-12 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 2547
E-13 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY 2549
E-14 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION 2552
E-15 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 2555
E-16 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY 2558
E-17 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 2559
E-18 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 2562
E-19 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 2566
E-20 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 2570
E-21 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL 2574
E-22 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP 2576
E-23 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP 2578
E-24 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION 2580
E-25 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 2584
E-26 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 2585
E-27 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2586
E-28 TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP 2588
E-29 INDICATION OF HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT 2589
E-30 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL 2591
E-31 ALARM BUZZER DOES NOT SOUND 2593
E-32 ALARM BUZZER DOES NOT STOP SOUNDING 2595
E-33 KICKDOWN DOES NOT WORK WHEN KICKDOWN SWITCH IS TURNED ON 2596
E-34 HOLD SWITCH DOES NOT WORK WHEN IT IS PRESSED 2598
E-35 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED 2600
E-36 TRANSMISSION CUT-OFF MODE IS NOT SELECTED OR NOT RELEASED 2604
E-37 TRANSMISSION CUT-OFF SETTING CANNOT BE RELEASED 2606
E-38 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED 2608
E-39 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE NORMALLY WHEN ENGINE POWER MODE SELECTOR SWITCH IS OPERATED 2610
E-40 FLOW OF LOADER PUMP DOES NOT INCREASE FROM THE MINIMUM RATE 2612
E-41 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED 2613
E-42 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED (FOR AJSS SPEC) 2615
E-43 HORN DOES NOT SOUND 2617
E-44 HORN DOES NOT SOUND (FOR AJSS SPEC) 2620
E-45 HORN DOES NOT STOP SOUNDING 2623
E-46 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 2626
E-47 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS (FOR AJSS SPEC) 2628
E-48 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT 2630
E-49 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2634
E-50 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT 2638
E-51 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2642
E-52 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 2646
E-53 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2648
E-54 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 2650
E-55 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2652
E-56 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT 2654
E-57 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT 2658
E-58 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT 2662
E-59 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2665
E-60 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT 2668
E-61 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2671
E-62 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT 2675
E-63 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED 2679
E-64 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT 2683
E-65 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND 2687
E-66 FRONT WIPER DOES NOT OPERATE 2689
E-67 FRONT WIPER DOES NOT OPERATE (FOR AJSS SPEC) 2693
E-68 REAR WIPER DOES NOT OPERATE 2697
E-69 REAR WIPER DOES NOT OPERATE (FOR AJSS SPEC) 2700
E-70 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY 2703
E-71 WINDOW WASHER DOES NOT OPERATE 2706
E-72 WINDOW WASHER DOES NOT OPERATE (FOR AJSS SPEC) 2709
E-73 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2712
E-74 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2713
E-75 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2715
E-76 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP 2716
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2718
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2718
FAILURE MODE AND CAUSE TABLE 2719
H-1 MACHINE DOES NOT START 2742
H-2 LOCKUP IS NOT RELEASED 2745
H-3 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE 2746
H-4 TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADABILITY IS LOW, OR GEAR SPEED DOES NOT SHIFT 2747
H-5 LARGE SHOCK IS MADE WHEN MACHINE MOVES OFF OR GEAR IS SHIFTED 2750
H-6 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED 2753
H-7 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 2756
H-8 MACHINE DOES NOT TURN (FOR STEERING WHEEL SPEC) 2758
H-9 MACHINE DOES NOT TURN (JOYSTICKSTEERING SPECIFICATION) 2760
H-10 MACHINE DOES NOT TURN (AJSS SPECIFICATION) 2762
H-11 TURNING RESPONSE IS POOR (FOR STEERING WHEEL SPEC) 2764
H-12 TURNING RESPONSE IS POOR (JOYSTICKSTEERING SPECIFICATION) 2766
H-13 TURNING RESPONSE IS POOR (AJSS SPECIFICATION) 2768
H-14 STEERING WHEEL IS HEAVY TO OPERATE 2770
H-15 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (FOR STEERING WHEEL SPEC) 2771
H-16 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (JOYSTICKSTEERING SPECIFICATION) 2773
H-17 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (AJSS SPECIFICATION) 2775
H-18 TURNING RADIUS DIFFERS BETWEEN RIGHT AND LEFT TURNS 2777
H-19 WHEEL BRAKES DO NOT WORK OR ARE WEAK 2778
H-20 WHEEL BRAKES ARE NOT RELEASED OR DRAG 2780
H-21 PARKING BRAKE DOES NOT WORK OR IT IS WEAK 2781
H-22 PARKING BRAKE IS NOT RELEASED OR DRAGS 2782
H-23 BOOM DOES NOT RISE 2784
H-24 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE 2786
H-25 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT 2788
H-26 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND 2789
H-27 HYDRAULIC DRIFT OF BOOM IS LARGE 2790
H-28 BOOM MOVES UP AND DOWN DURING OPERATION 2791
H-29 BUCKET DOES NOT TILT BACK 2792
H-30 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE 2794
H-31 BUCKET DECELERATES DURING TILT-BACK OPERATION 2796
H-32 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND 2797
H-33 HYDRAULIC DRIFT OF BUCKET IS LARGE 2798
H-34 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD) 2799
H-35 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE 2800
H-36 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE (MULTI-FUNCTION MONO-LEVER TYPE) 2801
H-37 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2802
H-38 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS 2803
H-39 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 2805
H-40 E C S S (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES 2806
H-41 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2807
H-42 UNUSUAL NOISE IS HEARD FROM AROUND FAN 2808
TROUBLESHOOTING OF ENGINE (S-MODE) 2809
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2809
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2810
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2811
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2812
S-4 ENGINE STARTABILITY IS POOR 2813
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2815
S-6 ENGINE STOPS DURING OPERATION 2817
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2819
S-8 ENGINE LACKS POWER 2820
S-9 KDPF GETS CLOGGED IN A SHORT TIME 2822
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2824
S-11 OIL BECOMES CONTAMINATED QUICKLY 2825
S-12 FUEL CONSUMPTION IS EXCESSIVE 2826
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2827
S-14 OIL PRESSURE DROPS 2828
S-15 FUEL MIXES INTO ENGINE OIL 2830
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2831
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2832
S-18 UNUSUAL NOISE IS HEARD 2833
S-19 VIBRATION IS EXCESSIVE 2834
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2835
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2836
S-22 ACTIVE REGENERATION TAKES TIME 2838
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2840
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2841
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2843
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2844
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM 2845
OUTLINE OF FAILURE DISPLAY 2845
TROUBLESHOOTING FOR FCS 2846
TROUBLESHOOTING FOR AUTO-GREASING PUMP 2847
REPLACEMENT OF PUMP ELEMENT 2850
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM 2851
REPLACEMENT OF AUTO-GREASING CONTROLLER 2853
PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING 2854
50 DISASSEMBLY AND ASSEMBLY 2855
CONTENTS 2856
ABBREVIATION LIST 2861
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2867
HOW TO READ THIS MANUAL 2867
COATING MATERIALS LIST 2869
SPECIAL TOOLS LIST 2873
SKETCHES OF SPECIAL TOOLS 2899
ENGINE AND COOLING SYSTEM 2908
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2908
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2909
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2911
REMOVE AND INSTALL INJECTOR ASSEMBLY 2918
METHOD FOR REMOVING INJECTOR ASSEMBLY 2919
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2929
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 2943
METHOD FOR REMOVING FUEL DOSER ASSEMBLY 2943
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY 2944
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2947
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2948
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2958
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2974
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2974
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2975
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2976
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2976
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2980
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2984
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2984
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2985
REMOVE AND INSTALL ALTERNATOR BELT 2987
METHOD FOR REMOVING ALTERNATOR BELT 2987
METHOD FOR INSTALLING ALTERNATOR BELT 2988
REMOVE AND INSTALL RADIATOR ASSEMBLY 2989
METHOD FOR REMOVING RADIATOR ASSEMBLY 2990
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2995
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 3001
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 3001
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 3004
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 3007
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 3007
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 3012
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 3019
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 3020
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 3024
REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY 3030
METHOD FOR REMOVING POWER TRAIN OIL COOLER ASSEMBLY 3030
METHOD FOR INSTALLING POWER TRAIN OIL COOLER ASSEMBLY 3032
REMOVE AND INSTALL ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 3035
METHOD FOR REMOVING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 3036
METHOD FOR INSTALLING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 3053
DISCONNECT AND CONNECT ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 3070
METHOD FOR DISCONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 3070
METHOD FOR CONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 3071
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 3072
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 3072
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 3073
REMOVE AND INSTALL ENGINE REAR OIL SEAL 3077
METHOD FOR REMOVING ENGINE REAR OIL SEAL 3077
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 3079
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 3085
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 3085
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 3089
REMOVE AND INSTALL FUEL TANK ASSEMBLY 3093
METHOD FOR REMOVING FUEL TANK ASSEMBLY 3093
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 3096
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 3099
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 3099
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 3108
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 3116
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 3116
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 3117
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 3120
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 3120
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 3121
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 3123
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 3123
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 3124
REMOVE AND INSTALL KDPF ASSEMBLY 3125
METHOD FOR REMOVING KDPF ASSEMBLY 3126
METHOD FOR INSTALLING KDPF ASSEMBLY 3129
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 3133
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 3133
METHOD FOR ASSEMBLING KDPF ASSEMBLY 3137
REMOVE AND INSTALL SCR ASSEMBLY 3143
METHOD FOR REMOVING SCR ASSEMBLY 3143
METHOD FOR INSTALLING SCR ASSEMBLY 3146
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 3151
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 3151
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 3154
REMOVE AND INSTALL KCCV ASSEMBLY 3158
METHOD FOR REMOVING KCCV ASSEMBLY 3158
METHOD FOR INSTALLING KCCV ASSEMBLY 3160
REMOVE AND INSTALL VGT ASSEMBLY 3163
METHOD FOR REMOVING VGT ASSEMBLY 3163
METHOD FOR INSTALLING VGT ASSEMBLY 3166
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 3170
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 3170
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 3173
REMOVE AND INSTALL AdBlue/DEF INJECTOR 3177
METHOD FOR REMOVING AdBlue/DEF INJECTOR 3177
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 3180
REMOVE AND INSTALL AdBlue/DEF PUMP 3183
METHOD FOR REMOVING AdBlue/DEF PUMP 3183
METHOD FOR INSTALLING AdBlue/DEF PUMP 3186
REMOVE AND INSTALL AdBlue/DEF HOSE 3189
METHOD FOR REMOVING AdBlue/DEF HOSE 3189
METHOD FOR INSTALLING AdBlue/DEF HOSE 3196
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 3204
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 3204
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 3207
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 3210
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 3210
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 3211
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 3214
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 3214
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 3215
POWER TRAIN 3217
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 3217
METHOD FOR DISCONNECTING TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 3217
CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 3223
REMOVE AND INSTALL FRONT DIFFERENTIAL ASSEMBLY 3229
METHOD FOR REMOVING FRONT DIFFERENTIAL ASSEMBLY 3229
METHOD FOR INSTALLING FRONT DIFFERENTIAL ASSEMBLY 3230
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY (SPECIFICATION WITH LSD) 3233
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY (SPECIFICATION WITH LSD) 3234
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY (SPECIFICATION WITH LSD) 3240
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY (SPECIFICATION WITHOUT LSD) 3253
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY (SPECIFICATION WITHOUT LSD) 3254
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY (SPECIFICATION WITHOUT LSD) 3259
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY 3269
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY 3270
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY 3278
DISASSEMBLE AND ASSEMBLE INPUT TRANSFER ASSEMBLY 3289
METHOD FOR DISASSEMBLING INPUT TRANSFER ASSEMBLY 3289
METHOD FOR ASSEMBLING INPUT TRANSFER ASSEMBLY 3293
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY 3299
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 3301
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 3320
DISASSEMBLE AND ASSEMBLE TRANSFER AND PARKING BRAKE ASSEMBLY 3342
METHOD FOR DISASSEMBLING TRANSFER AND PARKING BRAKE ASSEMBLY 3344
METHOD FOR ASSEMBLING TRANSFER AND PARKING BRAKE ASSEMBLY 3354
REMOVE AND INSTALL FRONT AXLE ASSEMBLY 3369
METHOD FOR REMOVING FRONT AXLE ASSEMBLY 3369
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY 3371
REMOVE AND INSTALL REAR AXLE ASSEMBLY 3373
METHOD FOR REMOVING REAR AXLE ASSEMBLY 3373
METHOD FOR INSTALLING REAR AXLE ASSEMBLY 3376
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY (FRONT, REAR) 3378
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY (FRONT, REAR) 3378
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY (FRONT, REAR) 3381
STEERING SYSTEM 3387
REMOVE AND INSTALL STEERING VALVE ASSEMBLY 3387
METHOD FOR REMOVING STEERING VALVE ASSEMBLY 3387
METHOD FOR INSTALLING STEERING VALVE ASSEMBLY 3389
REMOVE AND INSTALL ROTARY VALVE ASSEMBLY (FOR AJSS SPEC) 3391
METHOD FOR REMOVING ROTARY VALVE ASSEMBLY 3391
METHOD FOR INSTALLING ROTARY VALVE ASSEMBLY 3398
BRAKE SYSTEM 3408
DISASSEMBLE AND ASSEMBLE SLACK ADJUSTER ASSEMBLY 3408
METHOD FOR ASSEMBLING SLACK ADJUSTER ASSEMBLY 3408
DISASSEMBLE AND ASSEMBLE BRAKE ACCUMULATOR CHARGE VALVE ASSEMBLY 3409
METHOD FOR ASSEMBLING BRAKE ACCUMULATOR CHARGE VALVE ASSEMBLY 3409
REMOVE AND INSTALL BRAKE ASSEMBLY (FRONT, REAR) 3411
METHOD FOR REMOVING BRAKE ASSEMBLY (FRONT, REAR) 3411
METHOD FOR INSTALLING BRAKE ASSEMBLY (FRONT, REAR) 3413
DISASSEMBLE AND ASSEMBLE BRAKE ASSEMBLY (FRONT, REAR) 3415
METHOD FOR DISASSEMBLING BRAKE ASSEMBLY (FRONT, REAR) 3416
ASSEMBLE WHEEL BRAKE ASSEMBLY (FRONT, REAR) 3418
UNDERCARRIAGE AND FRAME 3424
REMOVE AND INSTALL CENTER HINGE PIN 3424
METHOD FOR REMOVING CENTER HINGE PIN 3425
METHOD FOR INSTALLING CENTER HINGE PIN 3431
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 3440
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 3440
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 3442
REMOVE AND INSTALL FULL-LENGTH FENDER ASSEMBLY 3445
METHOD FOR REMOVING FULL-LENGTH FENDER ASSEMBLY 3445
METHOD FOR INSTALLING FULL-LENGTH FENDER ASSEMBLY 3446
HYDRAULIC SYSTEM 3448
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 3448
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 3448
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 3454
REMOVE AND INSTALL WORK EQUIPMENT PUMP ASSEMBLY 3460
METHOD FOR REMOVING WORK EQUIPMENT PUMP ASSEMBLY 3461
METHOD FOR INSTALLING WORK EQUIPMENT PUMP ASSEMBLY 3464
REMOVE AND INSTALL DIVIDER VALVE ASSEMBLY 3468
METHOD FOR REMOVING DIVIDER VALVE ASSEMBLY 3468
METHOD FOR INSTALLING DIVIDER VALVE ASSEMBLY 3471
DISASSEMBLE AND ASSEMBLE STEERING CYLINDER ASSEMBLY 3473
METHOD FOR DISASSEMBLING STEERING CYLINDER ASSEMBLY 3473
METHOD FOR ASSEMBLING STEERING CYLINDER ASSEMBLY 3475
REMOVE AND INSTALL STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY 3478
METHOD FOR REMOVING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY 3479
METHOD FOR INSTALLING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY 3483
REMOVE AND INSTALL COOLING FAN PUMP ASSEMBLY 3487
METHOD FOR REMOVING COOLING FAN PUMP ASSEMBLY 3487
METHOD FOR INSTALLING COOLING FAN PUMP ASSEMBLY 3490
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 3493
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 3493
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 3496
WORK EQUIPMENT 3499
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 3499
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 3499
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 3503
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 3507
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 3507
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 3509
CAB AND ITS ATTACHMENTS 3514
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 3514
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 3515
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 3524
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 3534
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) 3534
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) 3535
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 3544
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 3544
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 3550
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 3555
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY 3555
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY 3557
REMOVE AND INSTALL SWITCH ASSEMBLY OF AJSS LEVER 3559
METHOD FOR REMOVING SWITCH ASSEMBLY OF AJSS LEVER 3559
METHOD FOR INSTALLING SWITCH ASSEMBLY OF AJSS LEVER 3561
REMOVE AND INSTALL SEAT BELT 3565
METHOD FOR REMOVING SEAT BELT 3565
METHOD FOR INSTALLING SEAT BELT 3565
ELECTRICAL SYSTEM 3567
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 3567
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 3567
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 3570
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY 3573
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY 3573
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY 3574
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 3577
METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY 3577
METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY 3577
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY 3579
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY 3579
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY 3581
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 3583
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 3583
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 3584
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3586
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 3586
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 3587
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 3589
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 3589
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 3590
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 3592
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 3592
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 3594
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 3596
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 3596
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 3597
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 3598
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 3598
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 3599
REMOVE AND INSTALL COMMUNICATION TERMINAL 3600
REMOVE COMMUNICATION TERMINAL 3600
INSTALL COMMUNICATION TERMINAL 3606
60 MAINTENANCE STANDARD 3613
CONTENTS 3614
ABBREVIATION LIST 3615
ENGINE AND COOLING SYSTEM 3621
MAINTENANCE STANDARD OF ENGINE MOUNT 3621
MAINTENANCE STANDARD OF JOINT 3623
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP 3624
MAINTENANCE STANDARD OF SERVO VALVE OF BRAKE AND COOLING FAN PUMP 3626
MAINTENANCE STANDARD OF COOLING FAN MOTOR 3627
POWER TRAIN 3629
MAINTENANCE STANDARD OF DRIVE SHAFT 3629
MAINTENANCE STANDARD OF CENTER SUPPORT 3630
MAINTENANCE STANDARD OF TORQUE CONVERTER 3631
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 3636
MAINTENANCE STANDARD OF TRANSMISSION 3637
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE 3645
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 3646
MAINTENANCE STANDARD OF TORQUE CONVERTER REGULATOR VALVE 3647
MAINTENANCE STANDARD OF MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE 3648
MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION RELIEF VALVE 3650
MAINTENANCE STANDARD OF FRONT AXLE 3651
MAINTENANCE STANDARD OF REAR AXLE 3652
MAINTENANCE STANDARD OF FRONT CONVENTIONAL DIFFERENTIAL 3653
MAINTENANCE STANDARD OF FRONT LIMITED SLIP DIFFERENTIAL 3657
MAINTENANCE STANDARD OF FINAL DRIVE 3659
STEERING SYSTEM 3661
MAINTENANCE STANDARD OF STEERING COLUMN 3661
MAINTENANCE STANDARD OF STEERING PUMP 3662
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING PUMP 3665
MAINTENANCE STANDARD OF STEERING VALVE 3666
MAINTENANCE STANDARD OF STEERING CYLINDER 3667
MAINTENANCE STANDARD OF DIVERTER VALVE 3669
MAINTENANCE STANDARD OF SECONDARY STEERING PUMP 3670
BRAKE SYSTEM 3671
MAINTENANCE STANDARD OF CHARGE VALVE 3671
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR 3673
MAINTENANCE STANDARD OF BRAKE VALVE 3674
MAINTENANCE STANDARD OF SLACK ADJUSTER 3675
MAINTENANCE STANDARD OF BRAKE 3676
MAINTENANCE STANDARD OF PARKING BRAKE 3678
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE 3680
UNDERCARRIAGE AND FRAME 3681
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 3681
HYDRAULIC SYSTEM 3686
MAINTENANCE STANDARD OF HYDRAULIC TANK 3686
MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP 3687
MAINTENANCE STANDARD OF POWER TRAIN CHARGE DUPLEX PUMP 3689
MAINTENANCE STANDARD OF CONTROL VALVE 3691
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE 3700
WORK EQUIPMENT 3701
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 3701
MAINTENANCE STANDARD OF BUCKET 3705
MAINTENANCE STANDARD OF LIFT CYLINDER 3707
MAINTENANCE STANDARD OF BUCKET CYLINDER 3708
80 APPENDIX 3709
CONTENTS 3710
ABBREVIATION LIST 3712
AIR CONDITIONER SYSTEM 3718
PRECAUTIONS FOR REFRIGERANT 3718
AIR CONDITIONER COMPONENT 3719
SPECIFICATIONS OF AIR CONDITIONER 3721
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3722
OUTLINE OF REFRIGERATION CYCLE 3723
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3725
AIR CONDITIONER UNIT 3725
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3725
FUNCTION OF AIR CONDITIONER UNIT 3726
COMPONENT PARTS OF AIR CONDITIONER UNIT 3727
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3727
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3727
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT 3728
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT 3728
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT 3728
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3728
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3728
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3729
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3729
FUNCTION OF DUAL PRESSURE SWITCH 3730
AIR CONDITIONER CONTROLLER 3731
STRUCTURE OF AIR CONDITIONER CONTROLLER 3731
COMPRESSOR 3732
STRUCTURE OF COMPRESSOR 3732
SPECIFICATIONS OF COMPRESSOR 3732
FUNCTION OF COMPRESSOR 3732
CONDENSER 3733
STRUCTURE OF CONDENSER 3733
SPECIFICATIONS OF CONDENSER 3733
FUNCTION OF CONDENSER 3733
RECEIVER DRIER 3734
STRUCTURE OF RECEIVER DRIER 3734
SPECIFICATIONS OF RECEIVER DRIER 3734
FUNCTION OF RECEIVER DRIER 3734
SENSORS FOR AIR CONDITIONER SYSTEM 3735
FUNCTION OF SUNLIGHT SENSOR 3735
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3735
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3736
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3738
AIR CONDITIONER SYSTEM DIAGRAM 3741
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3742
FUNCTION OF AIR CONDITIONER CONTROLLER 3743
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3744
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3750
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3751
CHECK TEMPERATURE CONTROL FUNCTION 3753
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION 3753
TEST VENT (MODE) CHANGEOVER 3755
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3755
TESTING FRESH/RECIRC AIR CHANGEOVER 3757
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3757
TEST EVAPORATOR TEMPERATURE SENSOR 3759
TEST RELAYS 3761
METHOD FOR TESTING RELAYS 3761
AIR CONDITIONER TROUBLESHOOTING CHART 1 3763
AIR CONDITIONER TROUBLESHOOTING CHART 2 3764
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3767
FAILURE CODE [879AKA] 3769
FAILURE CODE [879AKB] 3771
FAILURE CODE [879BKA] 3773
FAILURE CODE [879BKB] 3775
FAILURE CODE [879CKA] 3777
FAILURE CODE [879CKB] 3779
FAILURE CODE [879DKZ] 3781
FAILURE CODE [879EMC] 3783
FAILURE CODE [879FMC] 3786
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3789
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3792
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3795
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3799
TROUBLESHOOTING USING GAUGE PRESSURE 3801
CONNECTION OF SERVICE TOOL 3804
METHOD FOR CONNECTING SERVICE TOOL 3805
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3806
HANDLE COMPRESSOR OIL 3808
90 CIRCUIT DIAGRAMS 3811
CONTENTS 3812
ABBREVIATION LIST 3815
HYDRAULIC CIRCUIT DIAGRAM 3821
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3821
HYDRAULIC CIRCUIT DIAGRAM (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) 3825
HYDRAULIC CIRCUIT DIAGRAM (FOR AJSS SPEC) 3827
HYDRAULIC CIRCUIT DIAGRAM OF BRAKE SYSTEM 3829
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 3831
HYDRAULIC AUTO-GREASING DIAGRAM 3833
ELECTRICAL CIRCUIT DIAGRAM 3835
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3835
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (1/6) 3839
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (2/6) 3841
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (3/6) 3843
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (4/6) 3845
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (5/6) 3847
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (6/6) 3849
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/6) 3851
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/6) 3853
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/6) 3855
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/6) 3857
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/6) 3859
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/6) 3861
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (1/6) 3863
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (2/6) 3865
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (3/6) 3867
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (4/6) 3869
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (5/6) 3871
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (6/6) 3873
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (1/10) 3875
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (2/10) 3877
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (3/10) 3879
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (4/10) 3881
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (5/10) 3883
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (6/10) 3885
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (7/10) 3887
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (8/10) 3889
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (9/10) 3891
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (10/10) 3893
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/11) 3895
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/11) 3897
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/11) 3899
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/11) 3901
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/11) 3903
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/11) 3905
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/11) 3907
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/11) 3909
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (9/11) 3911
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (10/11) 3913
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (11/11) 3915
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (1/9) 3917
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (2/9) 3919
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (3/9) 3921
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (4/9) 3923
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (5/9) 3925
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (6/9) 3927
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (7/9) 3929
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (8/9) 3931
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (9/9) 3933
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/10) 3935
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/10) 3937
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/10) 3939
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/10) 3941
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/10) 3943
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/10) 3945
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/10) 3947
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/10) 3949
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (9/10) 3951
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (10/10) 3953
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (1/8) 3955
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (2/8) 3957
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (3/8) 3959
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (4/8) 3961
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (5/8) 3963
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (6/8) 3965
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (7/8) 3967
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (8/8) 3969
INDEX 3971

DESCRIPTION:

Komatsu WA500-8E0 Wheel Loader Shop Manual VENBM55000 – PDF DOWNLOAD

SERIAL NUMBERS H50151 and up

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

S.V 30/12/24