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KOMATSU WA900-8 WHEEL LOADER SHOP MANUAL SEN06740-04 – PDF DOWNLOAD
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KOMATSU WA900-8 WHEEL LOADER SHOP MANUAL SEN06740-04 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA900-8 WHEEL LOADER SHOP MANUAL SEN06740-04 – PDF DOWNLOAD
Language : English
Pages : 5952
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA900-8 WHEEL LOADER SHOP MANUAL SEN06740-04 – PDF DOWNLOAD
COVER............................................................................................................................................. 1 00 INDEX AND FOREWORD............................................................................................................................ 3 INDEX........................................................................................................................................ 4 FOREWORD, SAFETY, BASIC INFORMATION.......................................................................................................... 27 HOW TO READ THE SHOP MANUAL.............................................................................................................. 27 SAFETY NOTICE FOR OPERATION.............................................................................................................. 29 PRECAUTIONS TO PREVENT FIRE.............................................................................................................. 37 ACTIONS IF FIRE OCCURS................................................................................................................... 39 PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS.......................................................................................... 40 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT............................................................................................. 41 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS.................................................................................. 44 PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT......................................................................................... 50 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT........................................................................................... 52 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT......................................................................................... 53 PRACTICAL USE OF KOMTRAX................................................................................................................. 54 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER............................................................................................ 55 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER................................................................ 55 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER................................................................ 56 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER................................................................ 57 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS............................................................................... 59 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR................................................................................ 63 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR........................................................................ 64 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL...................................................................... 66 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH...................................................................... 67 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE................................................................. 69 HOW TO READ ELECTRICAL WIRE CODE......................................................................................................... 70 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD............................................................................................ 74 STANDARD TIGHTENING TORQUE TABLE......................................................................................................... 77 CONVERSION TABLE......................................................................................................................... 84 ABBREVIATION LIST........................................................................................................................ 89 01 SPECIFICATION................................................................................................................................. 93 CONTENTS..................................................................................................................................... 94 SPECIFICATIONS............................................................................................................................... 95 SPECIFICATION DRAWING.................................................................................................................... 95 SPECIFICATION DRAWING: WA900-8....................................................................................................... 95 SPECIFICATIONS........................................................................................................................... 97 SPECIFICATION: WA900-8............................................................................................................... 97 WEIGHT TABLE............................................................................................................................. 102 WEIGHT TABLE: WA900-8................................................................................................................ 102 FUEL, COOLANT, LUBRICANT................................................................................................................. 104 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.................................................................... 104 10 STRUCTURE AND FUNCTION........................................................................................................................ 107 CONTENTS..................................................................................................................................... 108 BOOT-UP SYSTEM............................................................................................................................... 114 LAYOUT DRAWING OF BOOT-UP SYSTEM......................................................................................................... 114 PRE-LUBRICATION SYSTEM................................................................................................................... 116 PRE-LUBRICATION SYSTEM DIAGRAM....................................................................................................... 116 FUNCTION OF PRE-LUBRICATION SYSTEM................................................................................................... 116 OPERATION OF PRE-LUBRICATION SYSTEM.................................................................................................. 118 SYSTEM OPERATING LAMP SYSTEM............................................................................................................. 120 SYSTEM OPERATING LAMP SYSTEM DIAGRAM................................................................................................. 120 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM............................................................................................. 120 OPERATION OF SYSTEM OPERATING LAMP SYSTEM............................................................................................ 120 BATTERY DISCONNECT SWITCH................................................................................................................ 121 FUNCTION OF BATTERY DISCONNECT SWITCH................................................................................................ 121 OPERATION OF BATTERY DISCONNECT SWITCH............................................................................................... 121 STARTING MOTOR DISCONNECT SWITCH......................................................................................................... 122 FUNCTION OF STARTING MOTOR DISCONNECT SWITCH......................................................................................... 122 PREHEATING SYSTEM........................................................................................................................ 123 PREHEATING SYSTEM DIAGRAM............................................................................................................ 123 FUNCTION OF AUTOMATIC PREHEATING SYSTEM.............................................................................................. 123 OPERATION OF AUTOMATIC PREHEATING SYSTEM............................................................................................. 124 FUNCTION OF MANUAL PREHEATING SYSTEM................................................................................................. 124 OPERATION OF MANUAL PREHEATING SYSTEM................................................................................................ 124 ENGINE SHUTDOWN SECONDARY SWITCH......................................................................................................... 125 FUNCTION OF ENGINE SHUTDOWN SECONDARY SWITCH......................................................................................... 125 OPERATION OF ENGINE SHUTDOWN SECONDARY SWITCH........................................................................................ 125 EMERGENCY ENGINE STOP SWITCH............................................................................................................. 126 FUNCTION OF EMERGENCY ENGINE STOP SWITCH............................................................................................. 126 OPERATION OF EMERGENCY ENGINE STOP SWITCH............................................................................................ 126 EXTERNAL POWER SUPPLY ENGINE PREHEATER................................................................................................... 127 FUNCTION OF EXTERNAL POWER SUPPLY ENGINE PREHEATER................................................................................... 127 ENGINE SYSTEM................................................................................................................................ 128 LAYOUT DRAWING OF ENGINE SYSTEM.......................................................................................................... 128 ENGINE CONTROL SYSTEM.................................................................................................................... 130 ENGINE CONTROL SYSTEM DIAGRAM........................................................................................................ 130 OPERATION OF ENGINE CONTROL SYSTEM................................................................................................... 131 ENGINE OUTPUT TORQUE CONTROL FUNCTION................................................................................................ 132 ENGINE AUTOMATIC WARM-UP FUNCTION.................................................................................................... 132 ENGINE POWER MODE SELECTOR SYSTEM........................................................................................................ 133 ENGINE POWER MODE SELECTOR SYSTEM DIAGRAM............................................................................................ 133 FUNCTION OF ENGINE POWER MODE SELECTOR SYSTEM........................................................................................ 133 OPERATION OF ENGINE POWER MODE SELECTOR SYSTEM....................................................................................... 133 AUTOMATIC IDLE STOP SYSTEM............................................................................................................... 134 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM............................................................................................... 134 RPM SET.................................................................................................................................. 135 FUNCTION OF RPM SET.................................................................................................................. 135 ENGINE SYSTEM............................................................................................................................ 137 DAMPER............................................................................................................................... 137 VGT.................................................................................................................................. 139 EGR SYSTEM........................................................................................................................... 143 EGR VALVE............................................................................................................................ 147 EGR COOLER........................................................................................................................... 149 KCCV SYSTEM.......................................................................................................................... 150 KCCV................................................................................................................................. 153 KDPF................................................................................................................................. 155 COOLING SYSTEM............................................................................................................................... 159 LAYOUT DRAWING OF COOLING SYSTEM......................................................................................................... 159 SPECIFICATIONS OF COOLING SYSTEM..................................................................................................... 161 COOLING FAN CONTROL SYSTEM............................................................................................................... 162 COOLING FAN CONTROL SYSTEM DIAGRAM................................................................................................... 162 FUNCTION OF COOLING FAN CONTROL SYSTEM............................................................................................... 163 COOLING SYSTEM........................................................................................................................... 166 COOLING FAN PUMP..................................................................................................................... 166 COOLING PUMP......................................................................................................................... 174 COOLING FAN MOTOR.................................................................................................................... 175 CONTROL SYSTEM............................................................................................................................... 181 LAYOUT DRAWING OF CONTROL SYSTEM PARTS................................................................................................... 181 MACHINE MONITOR SYSTEM................................................................................................................... 183 MACHINE MONITOR SYSTEM DIAGRAM....................................................................................................... 183 FUNCTION OF MACHINE MONITOR SYSTEM................................................................................................... 184 REARVIEW MONITOR SYSTEM.................................................................................................................. 185 REARVIEW MONITOR SYSTEM DIAGRAM...................................................................................................... 185 FUNCTION OF REARVIEW MONITOR SYSTEM.................................................................................................. 185 KOMTRAX Plus SYSTEM...................................................................................................................... 186 KOMTRAX Plus SYSTEM DIAGRAM.......................................................................................................... 186 FUNCTION OF KOMTRAX Plus SYSTEM...................................................................................................... 186 LOAD METER SYSTEM........................................................................................................................ 188 LOAD METER SYSTEM DIAGRAM............................................................................................................ 188 FUNCTION OF LOAD METER SYSTEM........................................................................................................ 188 MACHINE LOCK-OUT SYSTEM.................................................................................................................. 194 LAYOUT DRAWING OF MACHINE LOCK-OUT SYSTEM............................................................................................ 194 FUNCTION OF MACHINE LOCK-OUT SYSTEM.................................................................................................. 194 OPERATION OF MACHINE LOCK-OUT SYSTEM................................................................................................. 194 CONTROL SYSTEM........................................................................................................................... 196 MACHINE MONITOR...................................................................................................................... 196 SWITCH PANEL......................................................................................................................... 216 REARVIEW MONITOR..................................................................................................................... 217 REARVIEW CAMERA...................................................................................................................... 219 KOMTRAX TERMINAL..................................................................................................................... 220 KOMTRAX Plus CONTROLLER.............................................................................................................. 222 WIRELESS LAN UNIT.................................................................................................................... 227 TRANSMISSION CONTROLLER.............................................................................................................. 228 WORK EQUIPMENT CONTROLLER............................................................................................................ 232 MONITOR CONTROLLER................................................................................................................... 236 CAN TERMINATING RESISTOR............................................................................................................. 241 ENGINE CONTROLLER.................................................................................................................... 242 ACCELERATOR PEDAL.................................................................................................................... 255 FUEL FEED PUMP SWITCH................................................................................................................ 258 HYDRAULIC SYSTEM............................................................................................................................. 259 LAYOUT DRAWING OF HYDRAULIC SYSTEM....................................................................................................... 259 CLSS..................................................................................................................................... 260 STRUCTURE OF CLSS.................................................................................................................... 260 FUNCTION OF CLSS..................................................................................................................... 261 WORK EQUIPMENT PUMP CONTROL SYSTEM....................................................................................................... 263 SWASH PLATE CONTROL FUNCTION OF WORK EQUIPMENT PUMP.................................................................................. 263 PICKUP ASSISTANCE CONTROL FUNCTION OF WORK EQUIPMENT PUMP WHEN ENGINE SPEED IS LOW................................................... 263 STEERING PUMP CONTROL SYSTEM............................................................................................................. 265 SWASH PLATE CONTROL FUNCTION OF STEERING PUMP........................................................................................ 265 PICKUP ASSISTANCE CONTROL FUNCTION OF STEERING PUMP WHEN ENGINE SPEED IS LOW......................................................... 265 COMPONENT PARTS OF HYDRAULIC SYSTEM...................................................................................................... 266 HYDRAULIC TANK....................................................................................................................... 266 WORK EQUIPMENT PUMP.................................................................................................................. 270 STEERING PUMP........................................................................................................................ 289 PILOT BRAKE CHARGE PUMP.............................................................................................................. 305 PUMP ASSEMBLY (TO LUBRICATE TRANSMISSION AND TORQUE CONVERTER)....................................................................... 306 ACCUMULATOR CHARGE VALVE............................................................................................................. 307 CONTROL VALVE........................................................................................................................ 312 POWER TRAIN SYSTEM........................................................................................................................... 347 LAYOUT DRAWING OF POWER TRAIN SYSTEM..................................................................................................... 347 OPERATION OF POWER TRAIN SYSTEM...................................................................................................... 350 TRANSMISSION CONTROL SYSTEM.............................................................................................................. 351 TRANSMISSION CONTROL SYSTEM DIAGRAM.................................................................................................. 351 TRANSMISSION GEAR SHIFT CONTROL SYSTEM................................................................................................... 353 ELECTRIC MODULATION FUNCTION SYSTEM DIAGRAM.......................................................................................... 353 ELECTRIC MODULATION FUNCTION......................................................................................................... 354 GEAR SHIFT DISPLAY FUNCTION.......................................................................................................... 354 AUTOMATIC GEAR SHIFT FUNCTION........................................................................................................ 354 SHIFT HOLD FUNCTION.................................................................................................................. 355 KICKDOWN FUNCTION.................................................................................................................... 355 AUTOMATIC KICKDOWN FUNCTION.......................................................................................................... 356 HUNTING PREVENTION FUNCTION.......................................................................................................... 356 TRANSMISSION INITIAL LEARNING AND ECMV CURRENT ADJUSTMENT FUNCTION................................................................... 356 SHIFT POINT CHANGING FUNCTION........................................................................................................ 356 3RD GEAR SPEED LIMITATION FUNCTION................................................................................................... 357 TRANSMISSION PROTECTION FUNCTION......................................................................................................... 358 PROTECTION FUNCTION WHEN TRAVEL DIRECTION IS CHANGED................................................................................. 358 SHIFT DOWN PROTECTION FUNCTION....................................................................................................... 358 ENGINE OVERRUN PREVENTION FUNCTION................................................................................................... 359 NEUTRALIZER FUNCTION................................................................................................................. 359 MODULATION CLUTCH FUNCTION........................................................................................................... 359 TIRE SLIP CONTROL SYSTEM................................................................................................................. 362 TIRE SLIP CONTROL SYSTEM DIAGRAM..................................................................................................... 362 FUNCTION OF TIRE SLIP CONTROL SYSTEM................................................................................................. 362 OPERATION OF TIRE SLIP CONTROL SYSTEM................................................................................................ 362 POWER TRAIN SYSTEM....................................................................................................................... 364 DRIVE SHAFT.......................................................................................................................... 364 CENTER SUPPORT....................................................................................................................... 366 TORQUE FLOW ASSEMBLY................................................................................................................. 367 TORQUE CONVERTER..................................................................................................................... 368 VALVE ASSEMBLY (FOR MAIN RELIEF AND TORQUE CONVERTER RELIEF)......................................................................... 376 TORQUE CONVERTER REGULATOR VALVE..................................................................................................... 379 TRANSMISSION......................................................................................................................... 381 TRANSMISSION CONTROL VALVE........................................................................................................... 399 MODULATION CLUTCH ECMV............................................................................................................... 402 F, R, 1ST, 2ND, 3RD CLUTCH ECMV...................................................................................................... 405 TRANSMISSION LUBRICATION RELIEF VALVE................................................................................................ 410 AXLE................................................................................................................................. 411 DIFFERENTIAL......................................................................................................................... 414 FINAL DRIVE.......................................................................................................................... 417 AJSS KNOB............................................................................................................................ 419 SHIFT HOLD SWITCH.................................................................................................................... 420 KICKDOWN SWITCH...................................................................................................................... 421 WORK EQUIPMENT SYSTEM........................................................................................................................ 422 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM.................................................................................................. 422 WORK EQUIPMENT SYSTEM DIAGRAM............................................................................................................ 424 WORK EQUIPMENT CONTROL SYSTEM............................................................................................................ 426 WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE......................................................... 426 WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION............................................. 427 WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM............................................................................... 428 WORK EQUIPMENT LEVER OPERATION FUNCTION.............................................................................................. 428 BUCKET PRIORITY CONTROL FUNCTION..................................................................................................... 429 BOOM STOP MODULATION FUNCTION........................................................................................................ 429 WORK EQUIPMENT SHOCK REDUCTION FUNCTION.............................................................................................. 430 TILT SHOCK REDUCTION FUNCTION........................................................................................................ 430 DUMP SHOCK REDUCTION FUNCTION........................................................................................................ 431 WORK EQUIPMENT NEUTRAL LOCK SYSTEM....................................................................................................... 433 WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM........................................................................................... 433 FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM....................................................................................... 433 REMOTE POSITIONER SYSTEM................................................................................................................. 435 REMOTE BUCKET POSITIONER SYSTEM DIAGRAM.............................................................................................. 435 FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM.......................................................................................... 435 REMOTE BOOM POSITIONER SYSTEM DIAGRAM................................................................................................ 436 FUNCTION OF REMOTE BOOM POSITIONER SYSTEM............................................................................................ 436 BUCKET POSITIONER AND BOOM POSITIONER.................................................................................................... 440 STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER................................................................................... 440 AUTO-DIGGING SYSTEM...................................................................................................................... 441 AUTO-DIGGING SYSTEM DIAGRAM.......................................................................................................... 441 FUNCTION OF AUTO-DIGGING SYSTEM...................................................................................................... 441 SEMI-AUTO APPROACH SYSTEM................................................................................................................ 443 SEMI-AUTO APPROACH SYSTEM DIAGRAM.................................................................................................... 443 FUNCTION OF SEMI-AUTO APPROACH SYSTEM................................................................................................ 443 SEMI-AUTO DUMP SYSTEM.................................................................................................................... 444 SEMI-AUTO DUMP SYSTEM DIAGRAM........................................................................................................ 444 FUNCTION OF SEMI-AUTO DUMP SYSTEM.................................................................................................... 444 ECSS..................................................................................................................................... 446 ECSS DIAGRAM......................................................................................................................... 446 FUNCTION OF ECSS..................................................................................................................... 446 OPERATION OF ECSS.................................................................................................................... 446 WALL DIGGING PREVENTION CONTROL SYSTEM................................................................................................... 448 WALL DIGGING PREVENTION CONTROL SYSTEM DIAGRAM....................................................................................... 448 FUNCTION OF WALL DIGGING PREVENTION CONTROL SYSTEM................................................................................... 448 WORK EQUIPMENT SYSTEM.................................................................................................................... 450 SOLENOID VALVE (WORK EQUIPMENT LOCK)................................................................................................. 450 PILOT CIRCUIT ACCUMULATOR............................................................................................................ 451 ECSS CIRCUIT ACCUMULATOR............................................................................................................. 452 WORK EQUIPMENT ELECTRIC LEVER........................................................................................................ 453 STEERING SYSTEM.............................................................................................................................. 456 LAYOUT DRAWING OF STEERING SYSTEM........................................................................................................ 456 SECONDARY STEERING SYSTEM................................................................................................................ 457 SECONDARY STEERING SYSTEM DIAGRAM.................................................................................................... 457 FUNCTION OF SECONDARY STEERING SYSTEM................................................................................................ 457 AJSS..................................................................................................................................... 458 LAYOUT DRAWING OF AJSS............................................................................................................... 458 AJSS SYSTEM DIAGRAM.................................................................................................................. 459 FUNCTION OF AJSS..................................................................................................................... 460 NEUTRALIZER FUNCTION OF AJSS......................................................................................................... 461 AJSS NEUTRAL INTERLOCK FUNCTION...................................................................................................... 461 AJSS SPEED SENSING STEERING FUNCTION................................................................................................. 462 AJSS TURN SIGNAL PILOT LAMP CONTROL FUNCTION......................................................................................... 464 STEERING LOCK SYSTEM..................................................................................................................... 465 STEERING LOCK SYSTEM DIAGRAM......................................................................................................... 465 FUNCTION OF STEERING LOCK SYSTEM..................................................................................................... 465 STEERING SYSTEM.......................................................................................................................... 466 AJSS EPC VALVE....................................................................................................................... 466 SOLENOID VALVE (FOR STEERING LOCK)................................................................................................... 467 STEERING LOCK VALVE.................................................................................................................. 468 ROTARY VALVE......................................................................................................................... 469 STEERING VALVE....................................................................................................................... 473 DIVERTER VALVE....................................................................................................................... 487 SECONDARY STEERING RELIEF VALVE...................................................................................................... 490 SECONDARY STEERING PUMP.............................................................................................................. 492 LUBRICATION FOR HINGE PIN AND STEERING............................................................................................... 493 BRAKE SYSTEM................................................................................................................................. 494 LAYOUT DRAWING OF BRAKE SYSTEM........................................................................................................... 494 PARKING BRAKE CONTROL SYSTEM............................................................................................................. 497 PARKING BRAKE CONTROL SYSTEM DIAGRAM................................................................................................. 497 OPERATION OF PARKING BRAKE CONTROL SYSTEM............................................................................................ 497 BRAKE SYSTEM............................................................................................................................. 499 SOLENOID VALVE (PARKING BRAKE)....................................................................................................... 499 PARKING BRAKE EMERGENCY RELEASE VALVE................................................................................................ 501 BRAKE CIRCUIT ACCUMULATOR............................................................................................................ 502 BRAKE VALVE.......................................................................................................................... 503 SLACK ADJUSTER....................................................................................................................... 509 BRAKE................................................................................................................................ 512 PARKING BRAKE........................................................................................................................ 514 PARKING BRAKE CIRCUIT CHECK VALVE.................................................................................................... 517 PUMP ASSEMBLY (FOR BRAKE COOLING).................................................................................................... 518 AUTOMATIC GREASE SYSTEM...................................................................................................................... 519 LAYOUT DRAWING OF AUTOMATIC GREASE SYSTEM................................................................................................ 519 AUTOMATIC GREASE SYSTEM DIAGRAM.......................................................................................................... 522 SPECIFICATIONS OF AUTOMATIC GREASE SYSTEM................................................................................................ 523 FUNCTION OF AUTOMATIC GREASE SYSTEM...................................................................................................... 524 AUTOMATIC GREASE SYSTEM.................................................................................................................. 525 Automatic grease pump................................................................................................................ 525 AUTO-GREASING INJECTOR............................................................................................................... 527 LIFTING SYSTEM............................................................................................................................... 530 POWER LADDER SYSTEM...................................................................................................................... 530 LAYOUT DRAWING OF POWER LADDER SYSTEM................................................................................................ 530 POWER LADDER SYSTEM DIAGRAM.......................................................................................................... 531 FUNCTION OF POWER LADDER SYSTEM...................................................................................................... 532 OPERATION OF POWER LADDER SYSTEM..................................................................................................... 532 POWER LADDER SYSTEM...................................................................................................................... 534 POWER LADDER PUMP.................................................................................................................... 534 POWER LADDER RELIEF VALVE............................................................................................................ 536 SOLENOID VALVE (POWER LADDER SHOCK REDUCTION)........................................................................................ 537 SOLENOID VALVE (POWER LADDER RAISE AND LOWER SWITCH)................................................................................. 538 UNDERCARRIAGE AND FRAME...................................................................................................................... 539 FRAME, AXLE MOUNT AND HINGE PIN.......................................................................................................... 539 STRUCTURE OF FRAME, AXLE MOUNT AND HINGE PIN......................................................................................... 539 FUNCTION OF FRAME, AXLE MOUNT AND HINGE PIN.......................................................................................... 540 STRUCTURE OF LUBRICATION SYSTEM FOR UNDERCARRIAGE........................................................................................ 541 SERVICE CENTER........................................................................................................................... 542 SERVICE CENTER....................................................................................................................... 542 SERVICE CENTER SYSTEM DIAGRAM........................................................................................................ 543 FUNCTION OF SERVICE CENTER........................................................................................................... 543 GREASE REFILL AUTOMATIC STOP SYSTEM.................................................................................................. 544 TIRE..................................................................................................................................... 546 STRUCTURE OF RADIAL TIRE............................................................................................................. 546 FUNCTION OF RADIAL TIRE.............................................................................................................. 546 WORK EQUIPMENT............................................................................................................................... 547 STRUCTURE OF WORK EQUIPMENT.............................................................................................................. 547 STRUCTURE OF BUCKET...................................................................................................................... 548 STRUCTURE OF LUBRICATION SYSTEM FOR WORK EQUIPMENT....................................................................................... 549 CAB RELATED PARTS............................................................................................................................ 551 ROPS..................................................................................................................................... 551 STRUCTURE OF ROPS.................................................................................................................... 551 FUNCTION OF ROPS..................................................................................................................... 551 CAB...................................................................................................................................... 552 STRUCTURE OF CAB..................................................................................................................... 552 CAB MOUNT................................................................................................................................ 553 STRUCTURE OF CAB MOUNT............................................................................................................... 553 FUNCTION OF CAB MOUNT................................................................................................................ 553 20 STANDARD VALUE TABLE.......................................................................................................................... 555 CONTENTS..................................................................................................................................... 556 STANDARD VALUE TABLE FOR ENGINE.............................................................................................................. 557 STANDARD VALUE TABLE FOR ENGINE: WA900-8................................................................................................. 557 STANDARD VALUE TABLE FOR MACHINE............................................................................................................. 561 STANDARD VALUE TABLE FOR MACHINE: WA900-8................................................................................................ 561 MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE.................................................................................... 575 30 TESTING AND ADJUSTING......................................................................................................................... 579 CONTENTS..................................................................................................................................... 580 RELATED INFORMATION ON TESTING AND ADJUSTING................................................................................................. 584 TOOLS FOR TESTING AND ADJUSTING.......................................................................................................... 584 ENGINE AND COOLING SYSTEM.................................................................................................................... 591 TEST ENGINE SPEED........................................................................................................................ 591 TEST ENGINE SPEED.................................................................................................................... 591 TEST BOOST PRESSURE...................................................................................................................... 595 TEST BOOST PRESSURE ON MACHINE MONITOR............................................................................................... 595 TEST BOOST PRESSURE BY TESTING TOOL.................................................................................................. 596 TEST EXHAUST GAS TEMPERATURE............................................................................................................. 599 TEST EXHAUST GAS TEMPERATURE......................................................................................................... 599 TEST EXHAUST GAS COLOR................................................................................................................... 601 TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER........................................................................................ 601 TEST EXHAUST GAS COLOR BY SMOKE METER................................................................................................ 605 CHECK AND ADJUST VALVE CLEARANCE......................................................................................................... 609 CHECK VALVE CLEARANCE................................................................................................................ 609 ADJUST VALVE CLEARANCE............................................................................................................... 611 TEST COMPRESSION PRESSURE................................................................................................................ 612 TEST COMPRESSION PRESSURE............................................................................................................ 612 TEST BLOWBY PRESSURE..................................................................................................................... 616 TEST BLOWBY PRESSURE................................................................................................................. 616 TEST ENGINE OIL PRESSURE................................................................................................................. 621 TEST ENGINE OIL PRESSURE ON MACHINE MONITOR.......................................................................................... 621 TEST ENGINE OIL PRESSURE BY TESTING TOOL............................................................................................. 622 TEST EGR VALVE AND VGT OIL PRESSURE...................................................................................................... 624 TEST EGR VALVE AND VGT OIL PRESSURE.................................................................................................. 624 TEST FUEL PRESSURE....................................................................................................................... 626 TEST FUEL PRESSURE................................................................................................................... 626 TEST FUEL RETURN RATE AND LEAKAGE........................................................................................................ 628 TEST FUEL RETURN RATE AND LEAKAGE.................................................................................................... 629 BLEED AIR FROM FUEL SYSTEM............................................................................................................... 636 BLEED AIR FROM FUEL SYSTEM........................................................................................................... 636 TEST FUEL CIRCUIT FOR LEAKAGE............................................................................................................ 638 TEST FUEL CIRCUIT FOR LEAKAGE........................................................................................................ 638 TEST LOW PRESSURE CIRCUIT DEVICES........................................................................................................ 639 TEST LOW PRESSURE CIRCUIT DEVICES.................................................................................................... 639 CYLINDER CUT-OUT MODE OPERATION.......................................................................................................... 644 NO-INJECTION CRANKING OPERATION.......................................................................................................... 645 TEST KDPF AND MUFFLER STACK FOR LOOSENESS AND DAMAGE..................................................................................... 646 TEST KDPF AND MUFFLER STACK FOR LOOSENESS AND DAMAGE................................................................................. 646 TEST INSTALLATION OF CYLINDER HEAD COVER AND MANIFOLDS................................................................................... 647 TEST INSTALLATION OF CYLINDER HEAD COVER AND MANIFOLDS............................................................................... 647 TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS.............................................................................................. 648 TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS.......................................................................................... 648 CLEAN FUEL DOSER......................................................................................................................... 649 CLEAN FUEL DOSER..................................................................................................................... 649 WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER................................................................................... 652 WRITE INJECTOR COMPENSATION VALUE.................................................................................................... 652 WRITE CORRECTION FOR ASH IN SOOT ACCUMULATION TO ENGINE CONTROLLER....................................................................... 659 WRITE CORRECTION FOR ASH IN SOOT ACCUMULATION TO ENGINE CONTROLLER................................................................... 659 TEST AND ADJUST ALTERNATOR BELT TENSION.................................................................................................. 660 TEST ALTERNATOR BELT TENSION......................................................................................................... 660 ADJUST ALTERNATOR BELT TENSION....................................................................................................... 661 CHECK AND ADJUST AIR CONDITIONER COMPRESSOR BELT......................................................................................... 662 CHECK AIR CONDITIONER COMPRESSOR BELT................................................................................................ 662 ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION....................................................................................... 663 POWER TRAIN.................................................................................................................................. 664 TEST AND ADJUST POWER TRAIN OIL PRESSURE................................................................................................. 664 TEST POWER TRAIN OIL PRESSURE........................................................................................................ 666 ADJUST POWER TRAIN OIL PRESSURE...................................................................................................... 681 TEST MODULATION CLUTCH OUTPUT SPEED SENSOR............................................................................................... 683 TEST MODULATION CLUTCH OUTPUT SPEED SENSOR........................................................................................... 683 TEST TRANSMISSION OUTPUT SPEED SENSOR.................................................................................................... 684 TEST TRANSMISSION OUTPUT SPEED SENSOR................................................................................................ 684 ADJUST WHEEL SPEED SENSOR................................................................................................................ 686 ADJUST WHEEL SPEED SENSOR............................................................................................................ 686 FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT................................................................................ 687 FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT............................................................................ 687 MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE.................................................................................. 690 MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE.............................................................................. 690 TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE..................................................................................... 693 TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE................................................................................. 693 STEERING SYSTEM.............................................................................................................................. 694 TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE............................................................................................ 694 TEST STEERING CIRCUIT OIL PRESSURE................................................................................................... 694 ADJUST STEERING CIRCUIT OIL PRESSURE................................................................................................. 697 BRAKE SYSTEM................................................................................................................................. 699 RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT.................................................................................. 699 RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT.............................................................................. 699 TEST WHEEL BRAKE OIL PRESSURE............................................................................................................ 700 TEST WHEEL BRAKE OIL PRESSURE........................................................................................................ 700 TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE........................................................................................ 702 TEST BRAKE ACCUMULATOR CHARGE PRESSURE............................................................................................... 702 ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE............................................................................................. 704 TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE.............................................................................. 706 TEST ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE..................................................................................... 706 CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE................................................................................... 710 RELEASE NITROGEN GAS WHEN YOU DISPOSE OF ACCUMULATOR..................................................................................... 715 TEST BRAKE PERFORMANCE................................................................................................................... 716 TEST BRAKE PERFORMANCE............................................................................................................... 716 TEST BRAKE PEDAL......................................................................................................................... 717 TEST BRAKE PEDAL..................................................................................................................... 717 ADJUST RIGHT BRAKE PEDAL SWITCH.......................................................................................................... 719 ADJUST RIGHT BRAKE PEDAL SWITCH...................................................................................................... 719 BLEED AIR FROM BRAKE CIRCUIT............................................................................................................. 721 BLEED AIR FROM BRAKE CIRCUIT......................................................................................................... 721 TEST WEAR OF WHEEL BRAKE DISC............................................................................................................ 723 TEST WEAR OF WHEEL BRAKE DISC........................................................................................................ 723 TEST PARKING BRAKE OIL PRESSURE.......................................................................................................... 725 TEST PARKING BRAKE OIL PRESSURE...................................................................................................... 725 TEST PARKING BRAKE PERFORMANCE........................................................................................................... 727 TEST PARKING BRAKE PERFORMANCE....................................................................................................... 727 RELEASE PARKING BRAKE MANUALLY........................................................................................................... 728 RELEASE PARKING BRAKE MANUALLY....................................................................................................... 728 TEST WEAR AMOUNT OF PARKING BRAKE DISC................................................................................................... 730 TEST WEAR AMOUNT OF PARKING BRAKE DISC............................................................................................... 730 HYDRAULIC SYSTEM............................................................................................................................. 732 RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT................................................................................... 732 RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT............................................................................... 732 TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE.............................................................................................. 734 TEST WORK EQUIPMENT OIL PRESSURE..................................................................................................... 734 ADJUST WORK EQUIPMENT OIL PRESSURE................................................................................................... 739 TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE.......................................................................................... 741 TEST WORK EQUIPMENT EPC OIL PRESSURE................................................................................................. 741 ADJUST WORK EQUIPMENT EPC OIL PRESSURE............................................................................................... 743 BLEED AIR FROM HYDRAULIC CIRCUIT......................................................................................................... 744 BLEED AIR FROM HYDRAULIC CIRCUIT..................................................................................................... 744 TEST COOLING FAN SPEED................................................................................................................... 750 TEST COOLING FAN SPEED............................................................................................................... 750 TEST COOLING FAN CIRCUIT OIL PRESSURE.................................................................................................... 751 TEST COOLING FAN CIRCUIT OIL PRESSURE................................................................................................ 751 TEST COOLING FAN REVERSE SOLENOID OUTLET PRESSURE.................................................................................... 752 BLEED AIR FROM COOLING FAN CIRCUIT....................................................................................................... 755 BLEED AIR FROM COOLING PUMP.......................................................................................................... 755 BLEED AIR FROM FAN MOTOR CIRCUIT..................................................................................................... 756 TEST ECSS ACCUMULATOR CHARGE PRESSURE.................................................................................................... 757 TEST ECSS ACCUMULATOR CHARGE PRESSURE................................................................................................ 757 TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS..................................................... 759 TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE.......................................................................................... 759 CHARGE ECSS ACCUMULATOR WITH NITROGEN GAS............................................................................................ 762 WORK EQUIPMENT............................................................................................................................... 767 TEST AND ADJUST BUCKET POTENTIOMETER LEVER............................................................................................... 767 TEST BUCKET POTENTIOMETER LEVER...................................................................................................... 767 ADJUST BUCKET POTENTIOMETER LEVER.................................................................................................... 767 TEST AND ADJUST BOOM POTENTIOMETER LEVER................................................................................................. 769 TEST BOOM POTENTIOMETER LEVER........................................................................................................ 769 ADJUST BOOM POTENTIOMETER LEVER...................................................................................................... 769 CAB RELATED PARTS............................................................................................................................ 770 TEST WORK EQUIPMENT CONTROL LEVER........................................................................................................ 770 TEST WORK EQUIPMENT CONTROL LEVER.................................................................................................... 770 TEST AJSS LEVER.......................................................................................................................... 772 TEST OPERATING TIME OF AJSS LEVER.................................................................................................... 772 TEST OPERATING EFFORT OF AJSS LEVER.................................................................................................. 773 TEST OPERATING EFFORT OF DIRECTIONAL SWITCH.......................................................................................... 774 TEST OPERATING EFFORT OF GEAR SPEED SWITCH........................................................................................... 774 TEST AND ADJUST AJSS LEVER ANGLE SENSOR AND AJSS FRAME ANGLE SENSOR...................................................................... 775 TEST AJSS LEVER ANGLE SENSOR AND AJSS FRAME ANGLE SENSOR............................................................................. 775 ADJUST AJSS LEVER ANGLE SENSOR AND AJSS FRAME ANGLE SENSOR........................................................................... 775 TEST AND ADJUST STEERING STOPPER BOLT.................................................................................................... 777 TEST STEERING STOPPER BOLT........................................................................................................... 777 ADJUST STEERING STOPPER BOLT......................................................................................................... 777 ADJUST PLAY OF OPERATOR SEAT............................................................................................................. 778 ADJUST PLAY OF OPERATOR SEAT......................................................................................................... 778 ADJUST DOOR LOCK LINK.................................................................................................................... 779 ADJUST DOOR LOCK LINK................................................................................................................ 779 ELECTRICAL SYSTEM............................................................................................................................ 782 SETTING AND ADJUSTMENT OF EACH EQUIPMENT................................................................................................. 782 SETTING AND OPERATION OF MACHINE MONITOR................................................................................................. 786 OPERATOR MODE........................................................................................................................ 790 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN.......................................................................... 790 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN............................................................................. 790 CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)....................................................................................... 791 CHECK FUNCTION OF SERVICE METER AND ODOMETER......................................................................................... 792 USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD................................................................................... 792 SERVICE MODE......................................................................................................................... 796 SERVICE MODE......................................................................................................................... 796 CHECK PRE-DEFINED MONITORING INFORMATION............................................................................................. 798 CHECK MONITORING INFORMATION......................................................................................................... 804 ABNORMALITY RECORD MENU.............................................................................................................. 819 CHECK MAINTENANCE RECORD............................................................................................................. 823 MAINTENANCE MODE SETTING............................................................................................................. 825 PHONE NUMBER ENTRY SETTING........................................................................................................... 831 DEFAULT SETTING MENU................................................................................................................. 832 TESTING MENU......................................................................................................................... 850 ADJUSTMENT MENU...................................................................................................................... 863 NO-INJECTION CRANKING OPERATION...................................................................................................... 898 KOMTRAX SETTINGS MENU................................................................................................................ 901 DISPLAY SERVICE MESSAGE.............................................................................................................. 903 SNAP SHOT............................................................................................................................ 904 START UP KOMTRAX TERMINAL................................................................................................................ 907 DEFAULT SETTING OF KOMTRAX Plus CONTROLLER............................................................................................... 912 DEFAULT SETTING OF KOMTRAX Plus CONTROLLER........................................................................................... 912 DEFAULT SETTING OF WIRELESS LAN MODEM.................................................................................................... 915 DEFAULT SETTING OF WIRELESS LAN MODEM................................................................................................ 915 CHECK WIRELESS LAN MODEM COMMUNICATION............................................................................................... 916 DOWNLOAD DATA FROM KOMTRAX Plus CONTROLLER............................................................................................... 918 DOWNLOAD DATA FROM KOMTRAX Plus CONTROLLER........................................................................................... 918 Download data from service connector................................................................................................. 918 DOWNLOAD DATA FROM WIRELESS LAN...................................................................................................... 919 ADJUST AFTER REPLACEMENT OF KOMTRAX Plus CONTROLLER...................................................................................... 921 ADJUST AFTER REPLACEMENT OF KOMTRAX Plus CONTROLLER.................................................................................. 921 ADJUST AFTER REPLACEMENT OF WIRELESS LAN MODEM........................................................................................... 924 ADJUST AFTER REPLACEMENT OF WIRELESS LAN MODEM....................................................................................... 924 ADJUST REARVIEW CAMERA ANGLE............................................................................................................. 927 ADJUST REARVIEW CAMERA ANGLE......................................................................................................... 927 ENGINE CONTROLLER VOLTAGE CIRCUIT........................................................................................................ 928 BATTERY DISCONNECT SWITCH................................................................................................................ 929 TEST DIODES.............................................................................................................................. 930 TEST DIODES BY DIGITAL TESTER........................................................................................................ 930 TEST DIODES BY ANALOG TESTER......................................................................................................... 930 Pm-CLINIC.................................................................................................................................... 931 Pm-CLINIC SERVICE........................................................................................................................ 931 Pm CLINIC CHECK SHEET:WA900-8........................................................................................................ 934 PERFORM QUICK PM......................................................................................................................... 947 PERFORM QUICK PM..................................................................................................................... 947 40 TROUBLESHOOTING............................................................................................................................... 951 CONTENTS..................................................................................................................................... 952 RELATED INFORMATION TO TROUBLESHOOT.......................................................................................................... 967 GENERAL TROUBLESHOOTING POINTS........................................................................................................... 967 TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEM......................................................................................... 968 SEQUENCE OF EVENTS IN TROUBLESHOOTING.................................................................................................... 974 CHECKS BEFORE TROUBLESHOOTING............................................................................................................ 976 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING.............................................................................................. 978 WALK-AROUND CHECK.................................................................................................................... 978 TEST IN ACCORDANCE WITH TESTING PROCEDURE................................................................................................ 980 CHECK FUEL LEVEL AND TYPE............................................................................................................ 980 CHECK IMPURE INGREDIENT IN FUEL...................................................................................................... 980 REPLACE FUEL PREFILTER CARTRIDGE..................................................................................................... 981 REPLACE FUEL MAIN FILTER CARTRIDGE................................................................................................... 982 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE.............................................................................. 984 CHECK COOLANT LEVEL (RESERVOIR TANK)................................................................................................. 985 CHECK, CLEAN AND REPLACE AIR CLEANER................................................................................................. 986 CHECK HYDRAULIC OIL LEVEL............................................................................................................ 991 CHECK HYDRAULIC OIL FILTER OR HYDRAULIC OIL STRAINER................................................................................. 992 CHECK OIL LEVEL IN TRANSMISSION CASE................................................................................................. 993 CHECK OIL LEVEL IN AXLE CASE......................................................................................................... 995 BLEED AIR FROM FUEL SYSTEM........................................................................................................... 997 BLEED AIR FROM HYDRAULIC SYSTEM...................................................................................................... 997 CHECK ELECTRIC EQUIPMENT............................................................................................................. 997 PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM............................................................................................1004 CONNECT ADAPTER TO TROUBLESHOOT WORK EQUIPMENT CONTROLLER............................................................................1004 CONNECT ADAPTER TO TROUBLESHOOT ENGINE CONTROLLER....................................................................................1005 CONNECT ADAPTER TO TROUBLESHOOT TRANSMISSION CONTROLLER..............................................................................1006 CONNECT ADAPTER TO TROUBLESHOOT MONITOR CONTROLLER...................................................................................1007 CONNECT ADAPTER TO TROUBLESHOOT KOMTRAX TERMINAL.....................................................................................1010 CONNECT ADAPTER TO TROUBLESHOOT KOMTRAX Plus CONTROLLER..............................................................................1010 CONNECT ADAPTER TO TROUBLESHOOT KomVision CONTROLLER.................................................................................1011 CONNECT CONNECTORS FOR ENGINE RELATED PARTS..........................................................................................1011 DISCONNECT KomVision RADAR CONNECTOR.................................................................................................1015 PROCEDURE FOR TROUBLESHOOTING............................................................................................................1017 SYMPTOM AND TROUBLESHOOTING NUMBERS......................................................................................................1019 INFORMATION DESCRIBED IN TROUBLESHOOTING.................................................................................................1031 CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE........................................................................................1034 CONNECTOR LAYOUT.........................................................................................................................1262 CONNECTOR CONTACT IDENTIFICATION.........................................................................................................1278 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE..................................................................................................1320 FUSE LOCATION TABLE......................................................................................................................1326 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)..............................................................................1329 PREPARATION TO TROUBLESHOOT MACHINE MONITOR..............................................................................................1333 HARNESS CHECKER ON MACHINE MONITOR LCD UNIT..............................................................................................1335 PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883], [CB1883], [CA3135] AND [CB3135])..........................1340 FAILURE CODES TABLE......................................................................................................................1342 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)............................................................................................1372 FAILURE CODE [1500L0]....................................................................................................................1372 FAILURE CODE [15B0NX]....................................................................................................................1374 FAILURE CODE [15SAL1]....................................................................................................................1377 FAILURE CODE [15SALH]....................................................................................................................1380 FAILURE CODE [15SBL1]....................................................................................................................1383 FAILURE CODE [15SBLH]....................................................................................................................1386 FAILURE CODE [15SEL1]....................................................................................................................1389 FAILURE CODE [15SELH]....................................................................................................................1392 FAILURE CODE [15SFL1]....................................................................................................................1395 FAILURE CODE [15SFLH]....................................................................................................................1398 FAILURE CODE [15SGL1]....................................................................................................................1401 FAILURE CODE [15SGLH]....................................................................................................................1404 FAILURE CODE [15W0NT]....................................................................................................................1407 FAILURE CODE [2F00MA]....................................................................................................................1409 FAILURE CODE [2F00MB]....................................................................................................................1415 FAILURE CODE [2G42ZG]....................................................................................................................1420 FAILURE CODE [2G43ZG]....................................................................................................................1423 FAILURE CODE [879AKA]....................................................................................................................1426 FAILURE CODE [879AKB]....................................................................................................................1427 FAILURE CODE [879BKA]....................................................................................................................1428 FAILURE CODE [879BKB]....................................................................................................................1431 FAILURE CODE [879CKA]....................................................................................................................1434 FAILURE CODE [879CKB]....................................................................................................................1435 FAILURE CODE [879DKZ]....................................................................................................................1436 FAILURE CODE [879EMC]....................................................................................................................1440 FAILURE CODE [879FMC]....................................................................................................................1441 FAILURE CODE [879GKX]....................................................................................................................1442 FAILURE CODE [989A00]....................................................................................................................1445 FAILURE CODE [989L00]....................................................................................................................1446 FAILURE CODE [989M00]....................................................................................................................1447 FAILURE CODE [989N00]....................................................................................................................1448 FAILURE CODE [A1U0N3]....................................................................................................................1449 FAILURE CODE [A1U0N4]....................................................................................................................1453 FAILURE CODE [AA10NX]....................................................................................................................1457 FAILURE CODE [AB00KE]....................................................................................................................1460 FAILURE CODE [AB00KY]....................................................................................................................1463 FAILURE CODE [AQ10N3]....................................................................................................................1465 FAILURE CODE [B@BAZG]....................................................................................................................1468 FAILURE CODE [B@BAZK]....................................................................................................................1471 FAILURE CODE [B@BCNS]....................................................................................................................1474 FAILURE CODE [B@BCZK]....................................................................................................................1477 FAILURE CODE [B@C6NS]....................................................................................................................1480 FAILURE CODE [B@C7NS]....................................................................................................................1483 FAILURE CODE [B@CENS]....................................................................................................................1486 FAILURE CODE [B@GAZK]....................................................................................................................1489 FAILURE CODE [B@HANS]....................................................................................................................1492 FAILURE CODE [CA115].....................................................................................................................1495 FAILURE CODE [CA122].....................................................................................................................1500 FAILURE CODE [CA123].....................................................................................................................1503 FAILURE CODE [CA131].....................................................................................................................1507 FAILURE CODE [CA132].....................................................................................................................1510 FAILURE CODE [CA135].....................................................................................................................1513 FAILURE CODE [CA141].....................................................................................................................1516 FAILURE CODE [CA144].....................................................................................................................1519 FAILURE CODE [CA145].....................................................................................................................1522 FAILURE CODE [CA153].....................................................................................................................1525 FAILURE CODE [CA154].....................................................................................................................1529 FAILURE CODE [CA187].....................................................................................................................1533 FAILURE CODE [CA212].....................................................................................................................1537 FAILURE CODE [CA213].....................................................................................................................1540 FAILURE CODE [CA221].....................................................................................................................1543 FAILURE CODE [CA222].....................................................................................................................1546 FAILURE CODE [CA227].....................................................................................................................1550 FAILURE CODE [CA234].....................................................................................................................1553 FAILURE CODE [CA238].....................................................................................................................1555 FAILURE CODE [CA239].....................................................................................................................1558 FAILURE CODE [CA271].....................................................................................................................1561 FAILURE CODE [CA272].....................................................................................................................1564 FAILURE CODE [CA273].....................................................................................................................1566 FAILURE CODE [CA274].....................................................................................................................1569 FAILURE CODE [CA322].....................................................................................................................1571 FAILURE CODE [CA323].....................................................................................................................1574 FAILURE CODE [CA324].....................................................................................................................1577 FAILURE CODE [CA325].....................................................................................................................1580 FAILURE CODE [CA331].....................................................................................................................1583 FAILURE CODE [CA332].....................................................................................................................1586 FAILURE CODE [CA343].....................................................................................................................1589 FAILURE CODE [CA351].....................................................................................................................1596 FAILURE CODE [CA352].....................................................................................................................1604 FAILURE CODE [CA356].....................................................................................................................1608 FAILURE CODE [CA357].....................................................................................................................1612 FAILURE CODE [CA386].....................................................................................................................1616 FAILURE CODE [CA431].....................................................................................................................1620 FAILURE CODE [CA432].....................................................................................................................1624 FAILURE CODE [CA441].....................................................................................................................1629 FAILURE CODE [CA442].....................................................................................................................1633 FAILURE CODE [CA449].....................................................................................................................1637 FAILURE CODE [CA451].....................................................................................................................1640 FAILURE CODE [CA452].....................................................................................................................1643 FAILURE CODE [CA515].....................................................................................................................1646 FAILURE CODE [CA516].....................................................................................................................1648 FAILURE CODE [CA553].....................................................................................................................1651 FAILURE CODE [CA555].....................................................................................................................1654 FAILURE CODE [CA556].....................................................................................................................1657 FAILURE CODE [CA559].....................................................................................................................1660 FAILURE CODE [CA595].....................................................................................................................1666 FAILURE CODE [CA687].....................................................................................................................1669 FAILURE CODE [CA689].....................................................................................................................1673 FAILURE CODE [CA691].....................................................................................................................1678 FAILURE CODE [CA692].....................................................................................................................1681 FAILURE CODE [CA697].....................................................................................................................1684 FAILURE CODE [CA698].....................................................................................................................1686 FAILURE CODE [CA731].....................................................................................................................1688 FAILURE CODE [CA778].....................................................................................................................1696 FAILURE CODE [CA1117]....................................................................................................................1701 FAILURE CODE [CA1135]....................................................................................................................1706 FAILURE CODE [CA1257]....................................................................................................................1717 FAILURE CODE [CA1664]....................................................................................................................1719 LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE...................................................................................1721 FAILURE CODE [CA1691]....................................................................................................................1723 FAILURE CODE [CA1695]....................................................................................................................1728 FAILURE CODE [CA1696]....................................................................................................................1731 FAILURE CODE [CA1843]....................................................................................................................1734 FAILURE CODE [CA1844]....................................................................................................................1737 FAILURE CODE [CA1879]....................................................................................................................1740 FAILURE CODE [CA1881]....................................................................................................................1744 FAILURE CODE [CA1883]....................................................................................................................1748 LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE...................................................................................1751 FAILURE CODE [CA1921]....................................................................................................................1753 FAILURE CODE [CA1922]....................................................................................................................1761 FAILURE CODE [CA1923]....................................................................................................................1768 FAILURE CODE [CA1924]....................................................................................................................1771 Circuit diagram of fuel doser........................................................................................................1774 FAILURE CODE [CA1925]....................................................................................................................1776 Circuit diagram of fuel doser........................................................................................................1778 FAILURE CODE [CA1927]....................................................................................................................1780 FAILURE CODE [CA1928]....................................................................................................................1783 FAILURE CODE [CA1942]....................................................................................................................1786 FAILURE CODE [CA1963]....................................................................................................................1789 Circuit diagram of fuel doser........................................................................................................1795 FAILURE CODE [CA1977]....................................................................................................................1797 LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE...................................................................................1800 FAILURE CODE [CA1993]....................................................................................................................1801 LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE...................................................................................1803 FAILURE CODE [CA2185]....................................................................................................................1805 FAILURE CODE [CA2186]....................................................................................................................1808 FAILURE CODE [CA2249]....................................................................................................................1811 FAILURE CODE [CA2265]....................................................................................................................1818 FAILURE CODE [CA2266]....................................................................................................................1821 FAILURE CODE [CA2271]....................................................................................................................1824 FAILURE CODE [CA2272]....................................................................................................................1827 FAILURE CODE [CA2349]....................................................................................................................1831 FAILURE CODE [CA2353]....................................................................................................................1834 FAILURE CODE [CA2357]....................................................................................................................1836 FAILURE CODE [CA2381]....................................................................................................................1841 FAILURE CODE [CA2382]....................................................................................................................1844 FAILURE CODE [CA2383]....................................................................................................................1848 FAILURE CODE [CA2386]....................................................................................................................1852 FAILURE CODE [CA2387]....................................................................................................................1854 FAILURE CODE [CA2555]....................................................................................................................1858 FAILURE CODE [CA2556]....................................................................................................................1861 FAILURE CODE [CA2637]....................................................................................................................1864 FAILURE CODE [CA2639]....................................................................................................................1871 FAILURE CODE [CA2732]....................................................................................................................1880 FAILURE CODE [CA2733]....................................................................................................................1883 FAILURE CODE [CA2741]....................................................................................................................1886 Circuit diagram of fuel doser........................................................................................................1887 FAILURE CODE [CA2765]....................................................................................................................1889 FAILURE CODE [CA2777]....................................................................................................................1891 FAILURE CODE [CA2878]....................................................................................................................1894 Circuit diagram of fuel doser........................................................................................................1898 FAILURE CODE [CA2881]....................................................................................................................1900 LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE...................................................................................1904 FAILURE CODE [CA3133]....................................................................................................................1907 FAILURE CODE [CA3134]....................................................................................................................1910 FAILURE CODE [CA3135]....................................................................................................................1914 LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE...................................................................................1917 FAILURE CODE [CA3167]....................................................................................................................1919 Reset fuel doser memory..............................................................................................................1922 FAILURE CODE [CA3313]....................................................................................................................1925 FAILURE CODE [CA3314]....................................................................................................................1928 FAILURE CODE [CA3315]....................................................................................................................1931 LOADED DIAGNOSTICS OPERATION TO CONFIRM FAILURE CORRECTION...........................................................................1936 FAILURE CODE [CA3316]....................................................................................................................1938 FAILURE CODE [CA3317]....................................................................................................................1941 FAILURE CODE [CA3318]....................................................................................................................1944 LOADED DIAGNOSTICS OPERATION TO CONFIRM FAILURE CORRECTION...........................................................................1949 FAILURE CODE [CA3319]....................................................................................................................1951 FAILURE CODE [CA3321]....................................................................................................................1954 FAILURE CODE [CA3322]....................................................................................................................1957 LOADED DIAGNOSTICS OPERATION TO CONFIRM FAILURE CORRECTION...........................................................................1962 FAILURE CODE [CA3419]....................................................................................................................1964 FAILURE CODE [CA3421]....................................................................................................................1966 FAILURE CODE [CA4151]....................................................................................................................1969 FAILURE CODE [CA4158]....................................................................................................................1977 FAILURE CODE [CA4161]....................................................................................................................1980 FAILURE CODE [CA4162]....................................................................................................................1983 FAILURE CODE [CA4163]....................................................................................................................1986 LOADED DIAGNOSTICS OPERATION TO CONFIRM FAILURE CORRECTION...........................................................................1988 FAILURE CODE [CA4259]....................................................................................................................1989 FAILURE CODE [CA4952]....................................................................................................................1992 FAILURE CODE [CA5383]....................................................................................................................1995 FAILURE CODE [CB115].....................................................................................................................1997 FAILURE CODE [CB122].....................................................................................................................2002 FAILURE CODE [CB123].....................................................................................................................2005 FAILURE CODE [CB153].....................................................................................................................2009 FAILURE CODE [CB154].....................................................................................................................2013 FAILURE CODE [CB187].....................................................................................................................2017 FAILURE CODE [CB227].....................................................................................................................2021 FAILURE CODE [CB238].....................................................................................................................2024 FAILURE CODE [CB239].....................................................................................................................2027 FAILURE CODE [CB271].....................................................................................................................2030 FAILURE CODE [CB272].....................................................................................................................2033 FAILURE CODE [CB273].....................................................................................................................2035 FAILURE CODE [CB274].....................................................................................................................2038 FAILURE CODE [CB343].....................................................................................................................2040 FAILURE CODE [CB351].....................................................................................................................2047 FAILURE CODE [CB352].....................................................................................................................2055 FAILURE CODE [CB356].....................................................................................................................2059 FAILURE CODE [CB357].....................................................................................................................2063 FAILURE CODE [CB386].....................................................................................................................2067 FAILURE CODE [CB441].....................................................................................................................2070 FAILURE CODE [CB442].....................................................................................................................2074 FAILURE CODE [CB449].....................................................................................................................2078 FAILURE CODE [CB451].....................................................................................................................2081 FAILURE CODE [CB452].....................................................................................................................2084 FAILURE CODE [CB515].....................................................................................................................2087 FAILURE CODE [CB516].....................................................................................................................2089 FAILURE CODE [CB553].....................................................................................................................2092 FAILURE CODE [CB555].....................................................................................................................2095 FAILURE CODE [CB556].....................................................................................................................2098 FAILURE CODE [CB559].....................................................................................................................2101 FAILURE CODE [CB595].....................................................................................................................2107 FAILURE CODE [CB687].....................................................................................................................2110 FAILURE CODE [CB689].....................................................................................................................2114 FAILURE CODE [CB691].....................................................................................................................2119 FAILURE CODE [CB692].....................................................................................................................2122 FAILURE CODE [CB697].....................................................................................................................2125 FAILURE CODE [CB698].....................................................................................................................2127 FAILURE CODE [CB731].....................................................................................................................2129 FAILURE CODE [CB778].....................................................................................................................2138 FAILURE CODE [CB1117]....................................................................................................................2143 FAILURE CODE [CB1257]....................................................................................................................2148 FAILURE CODE [CB1548]....................................................................................................................2150 FAILURE CODE [CB1549]....................................................................................................................2153 FAILURE CODE [CB1551]....................................................................................................................2156 FAILURE CODE [CB1552]....................................................................................................................2159 FAILURE CODE [CB1553]....................................................................................................................2162 FAILURE CODE [CB1622]....................................................................................................................2165 FAILURE CODE [CB1664]....................................................................................................................2168 LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE...................................................................................2171 FAILURE CODE [CB1691]....................................................................................................................2172 FAILURE CODE [CB1695]....................................................................................................................2177 FAILURE CODE [CB1696]....................................................................................................................2180 FAILURE CODE [CB1843]....................................................................................................................2183 FAILURE CODE [CB1844]....................................................................................................................2186 FAILURE CODE [CB1879]....................................................................................................................2189 FAILURE CODE [CB1881]....................................................................................................................2193 FAILURE CODE [CB1883]....................................................................................................................2197 LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE...................................................................................2200 FAILURE CODE [CB1921]....................................................................................................................2202 FAILURE CODE [CB1922]....................................................................................................................2210 FAILURE CODE [CB1923]....................................................................................................................2217 FAILURE CODE [CB1924]....................................................................................................................2220 Circuit diagram of fuel doser........................................................................................................2223 FAILURE CODE [CB1925]....................................................................................................................2225 Circuit diagram of fuel doser........................................................................................................2227 FAILURE CODE [CB1927]....................................................................................................................2229 FAILURE CODE [CB1928]....................................................................................................................2232 FAILURE CODE [CB1942]....................................................................................................................2236 FAILURE CODE [CB1963]....................................................................................................................2239 Circuit diagram of fuel doser........................................................................................................2245 FAILURE CODE [CB1977]....................................................................................................................2247 LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE...................................................................................2250 FAILURE CODE [CB1993]....................................................................................................................2251 LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE...................................................................................2253 FAILURE CODE [CB2249]....................................................................................................................2255 FAILURE CODE [CB2265]....................................................................................................................2261 FAILURE CODE [CB2266]....................................................................................................................2264 FAILURE CODE [CB2271]....................................................................................................................2267 FAILURE CODE [CB2272]....................................................................................................................2270 FAILURE CODE [CB2349]....................................................................................................................2274 FAILURE CODE [CB2353]....................................................................................................................2277 FAILURE CODE [CB2357]....................................................................................................................2279 FAILURE CODE [CB2381]....................................................................................................................2284 FAILURE CODE [CB2382]....................................................................................................................2287 FAILURE CODE [CB2383]....................................................................................................................2291 FAILURE CODE [CB2386]....................................................................................................................2295 FAILURE CODE [CB2387]....................................................................................................................2297 FAILURE CODE [CB2637]....................................................................................................................2301 FAILURE CODE [CB2639]....................................................................................................................2308 FAILURE CODE [CB2732]....................................................................................................................2317 FAILURE CODE [CB2733]....................................................................................................................2320 FAILURE CODE [CB2741]....................................................................................................................2323 Circuit diagram of fuel doser........................................................................................................2324 FAILURE CODE [CB2765]....................................................................................................................2326 FAILURE CODE [CB2777]....................................................................................................................2328 FAILURE CODE [CB2878]....................................................................................................................2331 Circuit diagram of fuel doser........................................................................................................2335 FAILURE CODE [CB2881]....................................................................................................................2337 LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE...................................................................................2341 FAILURE CODE [CB3133]....................................................................................................................2344 FAILURE CODE [CB3134]....................................................................................................................2347 FAILURE CODE [CB3135]....................................................................................................................2351 LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE...................................................................................2354 FAILURE CODE [CB3167]....................................................................................................................2356 Reset fuel doser memory..............................................................................................................2359 FAILURE CODE [CB3313]....................................................................................................................2362 FAILURE CODE [CB3314]....................................................................................................................2365 FAILURE CODE [CB3315]....................................................................................................................2368 LOADED DIAGNOSTICS OPERATION TO CONFIRM FAILURE CORRECTION...........................................................................2373 FAILURE CODE [CB3316]....................................................................................................................2374 FAILURE CODE [CB3317]....................................................................................................................2377 FAILURE CODE [CB3318]....................................................................................................................2380 LOADED DIAGNOSTICS OPERATION TO CONFIRM FAILURE CORRECTION...........................................................................2385 FAILURE CODE [CB3319]....................................................................................................................2387 FAILURE CODE [CB3321]....................................................................................................................2390 FAILURE CODE [CB3322]....................................................................................................................2393 LOADED DIAGNOSTICS OPERATION TO CONFIRM FAILURE CORRECTION...........................................................................2398 FAILURE CODE [CB3419]....................................................................................................................2400 FAILURE CODE [CB3421]....................................................................................................................2402 FAILURE CODE [CB4151]....................................................................................................................2405 FAILURE CODE [CB4158]....................................................................................................................2413 FAILURE CODE [CB4161]....................................................................................................................2416 FAILURE CODE [CB4162]....................................................................................................................2419 FAILURE CODE [CB4163]....................................................................................................................2422 LOADED DIAGNOSTICS OPERATION TO CONFIRM FAILURE CORRECTION...........................................................................2424 FAILURE CODE [CB4259]....................................................................................................................2425 FAILURE CODE [CB4952]....................................................................................................................2428 FAILURE CODE [CB5383]....................................................................................................................2431 FAILURE CODE [D110L4]....................................................................................................................2433 FAILURE CODE [D162KA]....................................................................................................................2436 FAILURE CODE [D162KB]....................................................................................................................2437 FAILURE CODE [D162KY]....................................................................................................................2438 FAILURE CODE [D180KA]....................................................................................................................2439 FAILURE CODE [D180KB]....................................................................................................................2442 FAILURE CODE [D180KY]....................................................................................................................2445 FAILURE CODE [D191KA]....................................................................................................................2447 FAILURE CODE [D191KB]....................................................................................................................2450 FAILURE CODE [D191KY]....................................................................................................................2453 FAILURE CODE [D192KA]....................................................................................................................2455 FAILURE CODE [D192KB]....................................................................................................................2458 FAILURE CODE [D192KY]....................................................................................................................2461 FAILURE CODE [D19JKZ]....................................................................................................................2463 FAILURE CODE [D19LKA]....................................................................................................................2468 FAILURE CODE [D19LKB]....................................................................................................................2471 FAILURE CODE [D19LKY]....................................................................................................................2474 FAILURE CODE [D1E6KA]....................................................................................................................2476 FAILURE CODE [D1E6KB]....................................................................................................................2479 FAILURE CODE [D1E6KY]....................................................................................................................2482 FAILURE CODE [D1EFKA]....................................................................................................................2484 FAILURE CODE [D1EFKB]....................................................................................................................2487 FAILURE CODE [D1EFKY]....................................................................................................................2490 FAILURE CODE [D1J0KB]....................................................................................................................2493 FAILURE CODE [D5ZHKA]....................................................................................................................2496 FAILURE CODE [D5ZHKB]....................................................................................................................2499 FAILURE CODE [D5ZHKZ]....................................................................................................................2502 FAILURE CODE [D5ZHL6]....................................................................................................................2506 FAILURE CODE [D862KA]....................................................................................................................2509 FAILURE CODE [DA80KY]....................................................................................................................2512 FAILURE CODE [DA80L4]....................................................................................................................2515 FAILURE CODE [DAF0KT]....................................................................................................................2519 FAILURE CODE [DAF0MB]....................................................................................................................2520 FAILURE CODE [DAF0MC]....................................................................................................................2521 FAILURE CODE [DAF3KK]....................................................................................................................2522 FAILURE CODE [DAF8KB]....................................................................................................................2526 FAILURE CODE [DAFDKB]....................................................................................................................2529 FAILURE CODE [DAFGMC]....................................................................................................................2532 FAILURE CODE [DAFLKA]....................................................................................................................2533 FAILURE CODE [DAFLKB]....................................................................................................................2536 FAILURE CODE [DAFQKR]....................................................................................................................2539 FAILURE CODE [DAQ0KK]....................................................................................................................2550 FAILURE CODE [DAQ0KT]....................................................................................................................2555 FAILURE CODE [DAQ0MC]....................................................................................................................2556 FAILURE CODE [DAQ1KA]....................................................................................................................2557 FAILURE CODE [DAQ2KK]....................................................................................................................2560 FAILURE CODE [DAQ4KB]....................................................................................................................2564 FAILURE CODE [DAQ9KQ]....................................................................................................................2567 FAILURE CODE [DAQLKA]....................................................................................................................2569 FAILURE CODE [DAQLKB]....................................................................................................................2572 FAILURE CODE [DAQQKR]....................................................................................................................2575 FAILURE CODE [DAQRKR]....................................................................................................................2590 FAILURE CODE [DAQRMA]....................................................................................................................2604 FAILURE CODE [DAZ9KQ]....................................................................................................................2605 FAILURE CODE [DAZQKR]....................................................................................................................2607 FAILURE CODE [DB2QKR]....................................................................................................................2618 FAILURE CODE [DB2RKR]....................................................................................................................2636 FAILURE CODE [DB90KK]....................................................................................................................2654 FAILURE CODE [DB90KT]....................................................................................................................2659 FAILURE CODE [DB90MC]....................................................................................................................2660 FAILURE CODE [DB91KA]....................................................................................................................2661 FAILURE CODE [DB92KK]....................................................................................................................2664 FAILURE CODE [DB95KX]....................................................................................................................2669 FAILURE CODE [DB96KX]....................................................................................................................2672 FAILURE CODE [DB97KX]....................................................................................................................2677 FAILURE CODE [DB99KQ]....................................................................................................................2680 FAILURE CODE [DB9LKA]....................................................................................................................2682 FAILURE CODE [DB9LKB]....................................................................................................................2685 FAILURE CODE [DB9QKR]....................................................................................................................2688 FAILURE CODE [DB9RKR]....................................................................................................................2704 FAILURE CODE [DB9RMA]....................................................................................................................2720 FAILURE CODE [DBE5KX]....................................................................................................................2722 FAILURE CODE [DBE6KX]....................................................................................................................2725 FAILURE CODE [DBE7KX]....................................................................................................................2728 FAILURE CODE [DBP0KM]....................................................................................................................2732 FAILURE CODE [DBP0KT]....................................................................................................................2734 FAILURE CODE [DBP0NR]....................................................................................................................2735 FAILURE CODE [DBP5KP]....................................................................................................................2736 FAILURE CODE [DBPLKA]....................................................................................................................2740 FAILURE CODE [DBPLKB]....................................................................................................................2744 FAILURE CODE [DBPQKR]....................................................................................................................2747 FAILURE CODE [DBPRKR]....................................................................................................................2761 FAILURE CODE [DBPRMA]....................................................................................................................2774 FAILURE CODE [DBPUKR]....................................................................................................................2775 FAILURE CODE [DBPVKR]....................................................................................................................2785 FAILURE CODE [DBPWKR]....................................................................................................................2793 FAILURE CODE [DBPXKR]....................................................................................................................2795 FAILURE CODE [DBV0MC]....................................................................................................................2797 FAILURE CODE [DBV1KK]....................................................................................................................2798 FAILURE CODE [DBV5KX]....................................................................................................................2803 FAILURE CODE [DBV6KX]....................................................................................................................2807 FAILURE CODE [DBV7KX]....................................................................................................................2811 FAILURE CODE [DBV8KX]....................................................................................................................2812 FAILURE CODE [DBVLKA]....................................................................................................................2813 FAILURE CODE [DBVLKB]....................................................................................................................2817 FAILURE CODE [DBVQK4]....................................................................................................................2820 FAILURE CODE [DBVQKR]....................................................................................................................2834 FAILURE CODE [DBVRKR]....................................................................................................................2848 FAILURE CODE [DBVVKR]....................................................................................................................2862 FAILURE CODE [DBVWKR]....................................................................................................................2863 FAILURE CODE [DD1ALD]....................................................................................................................2865 FAILURE CODE [DDA8KB]....................................................................................................................2868 FAILURE CODE [DDA9KB]....................................................................................................................2871 FAILURE CODE [DDAAL6]....................................................................................................................2874 FAILURE CODE [DDACKA]....................................................................................................................2878 FAILURE CODE [DDACKY]....................................................................................................................2883 FAILURE CODE [DDADKA]....................................................................................................................2887 FAILURE CODE [DDADKY]....................................................................................................................2891 FAILURE CODE [DDB6L4]....................................................................................................................2893 FAILURE CODE [DDD1LD]....................................................................................................................2897 FAILURE CODE [DDDBKA]....................................................................................................................2900 FAILURE CODE [DDDBKY]....................................................................................................................2904 FAILURE CODE [DDE2KB]....................................................................................................................2907 FAILURE CODE [DDE2L6]....................................................................................................................2910 FAILURE CODE [DDE5KA]....................................................................................................................2912 FAILURE CODE [DDK4KA]....................................................................................................................2915 FAILURE CODE [DDK4KB]....................................................................................................................2919 FAILURE CODE [DDK5L4]....................................................................................................................2923 FAILURE CODE [DDNRKY]....................................................................................................................2926 FAILURE CODE [DDNTKY]....................................................................................................................2929 FAILURE CODE [DDNUKY]....................................................................................................................2932 FAILURE CODE [DDNWKY]....................................................................................................................2935 FAILURE CODE [DDNYKB]....................................................................................................................2937 FAILURE CODE [DDP5KA]....................................................................................................................2940 FAILURE CODE [DDP6KA]....................................................................................................................2943 FAILURE CODE [DDP6KY]....................................................................................................................2946 FAILURE CODE [DDP6NR]....................................................................................................................2949 FAILURE CODE [DDW9LD]....................................................................................................................2951 FAILURE CODE [DDWLLD]....................................................................................................................2954 FAILURE CODE [DF10KA]....................................................................................................................2957 FAILURE CODE [DF10KB]....................................................................................................................2958 FAILURE CODE [DGE5KA]....................................................................................................................2959 FAILURE CODE [DGE5KB]....................................................................................................................2962 FAILURE CODE [DGF1KA]....................................................................................................................2965 FAILURE CODE [DGF1KB]....................................................................................................................2968 FAILURE CODE [DGH2KX]....................................................................................................................2971 FAILURE CODE [DGR2KB]....................................................................................................................2974 FAILURE CODE [DGR2KZ]....................................................................................................................2978 FAILURE CODE [DGR4KB]....................................................................................................................2982 FAILURE CODE [DGR4KZ]....................................................................................................................2986 FAILURE CODE [DGT1KA]....................................................................................................................2990 FAILURE CODE [DGT1KB]....................................................................................................................2993 FAILURE CODE [DGT5KA]....................................................................................................................2996 FAILURE CODE [DGT5KY]....................................................................................................................3001 FAILURE CODE [DGT6KA]....................................................................................................................3005 FAILURE CODE [DGT6KY]....................................................................................................................3010 FAILURE CODE [DH21KA]....................................................................................................................3014 FAILURE CODE [DH21KY]....................................................................................................................3018 FAILURE CODE [DHA4KA]....................................................................................................................3021 FAILURE CODE [DHAAMA]....................................................................................................................3024 FAILURE CODE [DHABMA]....................................................................................................................3026 FAILURE CODE [DHACMA]....................................................................................................................3028 FAILURE CODE [DHADMA]....................................................................................................................3030 FAILURE CODE [DHPAKA]....................................................................................................................3032 FAILURE CODE [DHPAKY]....................................................................................................................3036 FAILURE CODE [DHPCKA]....................................................................................................................3039 FAILURE CODE [DHPCKY]....................................................................................................................3043 FAILURE CODE [DHPDKA]....................................................................................................................3046 FAILURE CODE [DHPDKY]....................................................................................................................3050 FAILURE CODE [DHPSKA]....................................................................................................................3053 FAILURE CODE [DHPSKY]....................................................................................................................3057 FAILURE CODE [DHT2L6]....................................................................................................................3060 FAILURE CODE [DHT3KX]....................................................................................................................3063 FAILURE CODE [DHT5KX]....................................................................................................................3067 FAILURE CODE [DHT7KX]....................................................................................................................3071 FAILURE CODE [DHT8KA]....................................................................................................................3075 FAILURE CODE [DHT8KY]....................................................................................................................3078 FAILURE CODE [DHTAKX]....................................................................................................................3080 FAILURE CODE [DHTBKA]....................................................................................................................3084 FAILURE CODE [DHTBKY]....................................................................................................................3088 FAILURE CODE [DHU2KA]....................................................................................................................3091 FAILURE CODE [DHU2KY]....................................................................................................................3094 FAILURE CODE [DHU3KA]....................................................................................................................3097 FAILURE CODE [DHU3KY]....................................................................................................................3100 FAILURE CODE [DJF1KA]....................................................................................................................3103 FAILURE CODE [DK30KA]....................................................................................................................3106 FAILURE CODE [DK30KY]....................................................................................................................3110 FAILURE CODE [DK55KA]....................................................................................................................3113 FAILURE CODE [DK55KY]....................................................................................................................3114 FAILURE CODE [DK55L5]....................................................................................................................3115 FAILURE CODE [DK59KA]....................................................................................................................3116 FAILURE CODE [DK59KY]....................................................................................................................3120 FAILURE CODE [DK59L8]....................................................................................................................3123 FAILURE CODE [DK5AKA]....................................................................................................................3128 FAILURE CODE [DK5AKY]....................................................................................................................3132 FAILURE CODE [DK5BKA]....................................................................................................................3135 FAILURE CODE [DK5BKY]....................................................................................................................3139 FAILURE CODE [DK5BL8]....................................................................................................................3142 FAILURE CODE [DK5CKA]....................................................................................................................3146 FAILURE CODE [DK5CKY]....................................................................................................................3150 FAILURE CODE [DKA0KA]....................................................................................................................3153 FAILURE CODE [DKA0KY]....................................................................................................................3157 FAILURE CODE [DKA0L0]....................................................................................................................3160 FAILURE CODE [DKA1KA]....................................................................................................................3163 FAILURE CODE [DKA1KY]....................................................................................................................3167 FAILURE CODE [DKD0KA]....................................................................................................................3170 FAILURE CODE [DKD0KY]....................................................................................................................3173 FAILURE CODE [DKD0L8]....................................................................................................................3175 FAILURE CODE [DKR2KX]....................................................................................................................3177 FAILURE CODE [DKR2NX]....................................................................................................................3181 FAILURE CODE [DKR3KX]....................................................................................................................3184 FAILURE CODE [DKR3NX]....................................................................................................................3188 FAILURE CODE [DLFAKA]....................................................................................................................3191 FAILURE CODE [DLFALC]....................................................................................................................3194 FAILURE CODE [DLFFLC]....................................................................................................................3197 FAILURE CODE [DLM3KA]....................................................................................................................3201 FAILURE CODE [DLM3LC]....................................................................................................................3204 FAILURE CODE [DLT3KA]....................................................................................................................3207 FAILURE CODE [DLT3LC]....................................................................................................................3210 FAILURE CODE [DLT4KB]....................................................................................................................3213 FAILURE CODE [DLT4KX]....................................................................................................................3216 FAILURE CODE [DNDBL4]....................................................................................................................3219 FAILURE CODE [DPQ1KR]....................................................................................................................3222 FAILURE CODE [DPQ1LD]....................................................................................................................3228 FAILURE CODE [DPQ2KR]....................................................................................................................3234 FAILURE CODE [DPQ3KR]....................................................................................................................3241 FAILURE CODE [DPQ4KB]....................................................................................................................3247 FAILURE CODE [DQ11KQ]....................................................................................................................3249 SENSOR ADDRESSES LIST................................................................................................................3253 FAILURE CODE [DQ11KR]....................................................................................................................3254 FAILURE CODE [DQ11KT]....................................................................................................................3257 FAILURE CODE [DQ11MA]....................................................................................................................3260 FAILURE CODE [DQ11NR]....................................................................................................................3264 FAILURE CODE [DQ12KQ]....................................................................................................................3267 SENSOR ADDRESSES LIST................................................................................................................3271 FAILURE CODE [DQ12KR]....................................................................................................................3272 FAILURE CODE [DQ12KT]....................................................................................................................3275 FAILURE CODE [DQ12MA]....................................................................................................................3278 FAILURE CODE [DQ12NR]....................................................................................................................3282 FAILURE CODE [DQ13KQ]....................................................................................................................3285 SENSOR ADDRESSES LIST................................................................................................................3289 FAILURE CODE [DQ13KR]....................................................................................................................3290 FAILURE CODE [DQ13KT]....................................................................................................................3293 FAILURE CODE [DQ13MA]....................................................................................................................3296 FAILURE CODE [DQ13NR]....................................................................................................................3300 FAILURE CODE [DQ14KQ]....................................................................................................................3303 SENSOR ADDRESSES LIST................................................................................................................3307 FAILURE CODE [DQ14KR]....................................................................................................................3308 FAILURE CODE [DQ14KT]....................................................................................................................3311 FAILURE CODE [DQ14MA]....................................................................................................................3314 FAILURE CODE [DQ14NR]....................................................................................................................3319 FAILURE CODE [DR10KA]....................................................................................................................3322 FAILURE CODE [DR20KA]....................................................................................................................3326 FAILURE CODE [DR30KA]....................................................................................................................3330 FAILURE CODE [DR40KA]....................................................................................................................3334 FAILURE CODE [DR50KA]....................................................................................................................3338 FAILURE CODE [DR60KA]....................................................................................................................3342 FAILURE CODE [DSJ0KR]....................................................................................................................3346 FAILURE CODE [DT22KB]....................................................................................................................3356 FAILURE CODE [DUMBKB]....................................................................................................................3359 FAILURE CODE [DV00KB]....................................................................................................................3362 FAILURE CODE [DV01KB]....................................................................................................................3365 FAILURE CODE [DW4PKA]....................................................................................................................3368 FAILURE CODE [DW4PKB]....................................................................................................................3371 FAILURE CODE [DW4PKY]....................................................................................................................3374 FAILURE CODE [DW4QKA]....................................................................................................................3377 FAILURE CODE [DW4QKB]....................................................................................................................3380 FAILURE CODE [DW4QKY]....................................................................................................................3383 FAILURE CODE [DW4RKA]....................................................................................................................3386 FAILURE CODE [DW4RKB]....................................................................................................................3389 FAILURE CODE [DW4RKY]....................................................................................................................3392 FAILURE CODE [DW4SKA]....................................................................................................................3395 FAILURE CODE [DW4SKB]....................................................................................................................3398 FAILURE CODE [DW4SKY]....................................................................................................................3401 FAILURE CODE [DW5PKA]....................................................................................................................3404 FAILURE CODE [DW5PKB]....................................................................................................................3407 FAILURE CODE [DW5PKY]....................................................................................................................3410 FAILURE CODE [DW5QKA]....................................................................................................................3413 FAILURE CODE [DW5QKB]....................................................................................................................3416 FAILURE CODE [DW5QKY]....................................................................................................................3419 FAILURE CODE [DW5RKA]....................................................................................................................3422 FAILURE CODE [DW5RKB]....................................................................................................................3425 FAILURE CODE [DW5RKY]....................................................................................................................3428 FAILURE CODE [DW5SKA]....................................................................................................................3431 FAILURE CODE [DW5SKB]....................................................................................................................3434 FAILURE CODE [DW5SKY]....................................................................................................................3437 FAILURE CODE [DW7BKA]....................................................................................................................3440 FAILURE CODE [DW7BKB]....................................................................................................................3443 FAILURE CODE [DW7BKY]....................................................................................................................3446 FAILURE CODE [DWM1KA]....................................................................................................................3448 FAILURE CODE [DWM1KB]....................................................................................................................3451 FAILURE CODE [DWM1KY]....................................................................................................................3454 FAILURE CODE [DWN6KA]....................................................................................................................3456 FAILURE CODE [DWN6KB]....................................................................................................................3459 FAILURE CODE [DWN6KY]....................................................................................................................3462 FAILURE CODE [DWN8KA]....................................................................................................................3465 FAILURE CODE [DWN8KB]....................................................................................................................3468 FAILURE CODE [DWN8KY]....................................................................................................................3471 FAILURE CODE [DWNFKA]....................................................................................................................3474 FAILURE CODE [DWNFKB]....................................................................................................................3477 FAILURE CODE [DWNFKY]....................................................................................................................3480 FAILURE CODE [DWNVKA]....................................................................................................................3482 FAILURE CODE [DWNVKB]....................................................................................................................3485 FAILURE CODE [DWNVKY]....................................................................................................................3488 FAILURE CODE [DX16KA]....................................................................................................................3490 FAILURE CODE [DX16KB]....................................................................................................................3493 FAILURE CODE [DX16KY]....................................................................................................................3496 FAILURE CODE [DXA1KA]....................................................................................................................3498 FAILURE CODE [DXA1KB]....................................................................................................................3501 FAILURE CODE [DXA1KY]....................................................................................................................3504 FAILURE CODE [DXA8KA]....................................................................................................................3506 FAILURE CODE [DXA8KB]....................................................................................................................3509 FAILURE CODE [DXA8KY]....................................................................................................................3512 FAILURE CODE [DXANKA]....................................................................................................................3514 FAILURE CODE [DXANKB]....................................................................................................................3517 FAILURE CODE [DXANKY]....................................................................................................................3520 FAILURE CODE [DXF0KA]....................................................................................................................3522 FAILURE CODE [DXF0KB]....................................................................................................................3525 FAILURE CODE [DXF0KY]....................................................................................................................3528 FAILURE CODE [DXF5KA]....................................................................................................................3530 FAILURE CODE [DXF5KB]....................................................................................................................3533 FAILURE CODE [DXF5KY]....................................................................................................................3536 FAILURE CODE [DXF6KA]....................................................................................................................3538 FAILURE CODE [DXF6KB]....................................................................................................................3541 FAILURE CODE [DXF6KY]....................................................................................................................3544 FAILURE CODE [DXH4KA]....................................................................................................................3546 FAILURE CODE [DXH4KB]....................................................................................................................3549 FAILURE CODE [DXH4KY]....................................................................................................................3552 FAILURE CODE [DXH5KA]....................................................................................................................3554 FAILURE CODE [DXH5KB]....................................................................................................................3557 FAILURE CODE [DXH5KY]....................................................................................................................3560 FAILURE CODE [DXH6KA]....................................................................................................................3562 FAILURE CODE [DXH6KB]....................................................................................................................3565 FAILURE CODE [DXH6KY]....................................................................................................................3568 FAILURE CODE [DXH7KA]....................................................................................................................3570 FAILURE CODE [DXH7KB]....................................................................................................................3573 FAILURE CODE [DXH7KY]....................................................................................................................3576 FAILURE CODE [DXH8KA]....................................................................................................................3578 FAILURE CODE [DXH8KB]....................................................................................................................3581 FAILURE CODE [DXH8KY]....................................................................................................................3584 FAILURE CODE [DXHPKA]....................................................................................................................3586 FAILURE CODE [DXHPKB]....................................................................................................................3589 FAILURE CODE [DXHPKY]....................................................................................................................3592 FAILURE CODE [DXHPMA]....................................................................................................................3595 FAILURE CODE [DXHPMB]....................................................................................................................3598 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)................................................................................................3601 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)............................................................................................3601 MANUAL PREHEATING SYSTEM DOES NOT WORK...................................................................................................3616 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK (FOR MACHINES WITHOUT PRE-LUBRICATION SYSTEM)..................................................3624 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK (FOR MACHINES WITH PRE-LUBRICATION SYSTEM).....................................................3631 WHILE PREHEATING IS IN OPERATION, PREHEATING DISPLAY DOES NOT LIGHT UP...................................................................3638 NONE OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY ANYTHING...........................................................3642 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING.............................................................................................3652 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL (BACKLIGHT GOES OFF OR FLICKERS)....................................................3655 LCD UNIT ON MACHINE MONITOR IS ABNORMAL..................................................................................................3658 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL........................................................................................3661 NIGHT MODE LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL.............................................................................3666 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL.............................................................................................3670 NIGHT MODE LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCHES DOES NOT OPERATE PROPERLY.....................................3675 TWO SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION..............................................................3680 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL.......................................................................................3685 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY.....................................................3690 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS.................................................................................3691 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY........................................................................................3696 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED...........................................................................................3702 NIGHT MODE LAMP OF REARVIEW MONITOR IS ABNORMAL..........................................................................................3708 AIR CLEANER CLOGGING CAUTION LAMP DOES NOT LIGHT UP......................................................................................3712 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP....................................................................................3715 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT UP WHEN PARKING BRAKE IS ON (PARKING) POSITION...............................................3718 BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE IS LOW.......................................3727 BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE IS LOW........................................3731 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL.........................................................................................3735 TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT RISE OR TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP..................3738 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT RISE OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP................................3740 SEATBELT CAUTION LAMP DOES NOT INDICATE NORMALLY.........................................................................................3742 ALARM BUZZER DOES NOT SOUND..............................................................................................................3745 ALARM BUZZER DOES NOT STOP...............................................................................................................3747 KICKDOWN DOES NOT OPERATE WHEN KICKDOWN SWITCH IS ON POSITION............................................................................3749 HOLD DOES NOT OPERATE WHEN HOLD SWITCH IS ON POSITION....................................................................................3752 PARKING BRAKE DOES NOT OPERATE EVEN IF IT IS APPLIED, OR THE BRAKE DRAGS IN FORWARD OR REVERSE TRAVEL WHEN PARKING BRAKE IS RELEASED.....3755 LOADER PUMP1 OR LOADER PUMP 2 IS FIXED TO THE MINIMUM FLOW...............................................................................3763 ECSS DOES NOT OPERATE OR CANNOT BE DEACTIVATED...........................................................................................3766 HORN DOES NOT SOUND......................................................................................................................3769 HORN DOES NOT STOP.......................................................................................................................3774 NONE OF HEADLAMP, CLEARANCE LAMP, OR TAIL LAMP LIGHTS UP.................................................................................3777 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OFF...................................................................................3781 HEADLAMP DO NOT LIGHT UP OR GO OFF.......................................................................................................3787 SIDE WORKING LAMP DOES NOT LIGHT UP OR GO OFF............................................................................................3793 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OFF...........................................................................................3798 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OFF............................................................................................3805 NONE OF TURN SIGNAL LAMP OR HAZARD LAMP LIGHTS UP OR GO OFF..............................................................................3812 TURN SIGNAL LAMP DOES NOT LIGHT UP OR GO OFF.............................................................................................3818 HAZARD LAMP DOES NOT LIGHT UP OR GO OFF..................................................................................................3825 BRAKE LAMP DOES NOT LIGHT UP OR STAYS LIT................................................................................................3831 BACKUP LAMP DOES NOT LIGHT UP OR STAYS LIT...............................................................................................3836 STAIRCASE LIGHT DOES NOT LIGHT UP OR GO OFF..............................................................................................3840 ENGINE ROOM LAMP DOES NOT LIGHT UP OR GO OFF.............................................................................................3846 FOG LAMP DOES NOT LIGHT UP OR GO OFF.....................................................................................................3851 YELLOW REVOLVING LAMP DOES NOT LIGHT UP OR GO OFF........................................................................................3856 BACKUP BUZZER DOES NOT SOUND OR DOES NOT STOP............................................................................................3861 FRONT WIPER DOES NOT OPERATE.............................................................................................................3865 REAR WIPER DOES NOT OPERATE..............................................................................................................3870 SIDE WIPER DOES NOT OPERATE..............................................................................................................3875 FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY...........................................................................3880 FRONT WINDOW WASHER DOES NOT OPERATE.....................................................................................................3888 REAR WINDOW WASHER DOES NOT OPERATE......................................................................................................3892 SIDE WINDOW WASHER DOES NOT OPERATE......................................................................................................3896 POWER LADDER DOES NOT OPERATE............................................................................................................3900 SHOCK IS LARGE WHEN POWER LADDER STOPS...................................................................................................3907 PARKING STATUS CANNOT BE CANCELLED WHILE POWER LADDER IS STORED..........................................................................3911 AUTO-DIGGING FUNCTION DOES NOT OPERATE...................................................................................................3914 SEMI-AUTO APPROACH FUNCTION DOES NOT OPERATE.............................................................................................3918 SEMI-AUTO DUMP FUNCTION DOES NOT OPERATE.................................................................................................3922 KOMTRAX Plus SYSTEM DOES NOT OPERATE NORMALLY............................................................................................3927 DATA DOWNLOAD WITH WIRELESS LAN DOES NOT OPERATE.........................................................................................3930 KomVision MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS................................................................................3931 KomVision MONITOR IMAGES ARE NOT DISPLAYED CLEARLY.......................................................................................3936 KomVision MONITOR BRIGHTNESS CANNOT BE ADJUSTED..........................................................................................3944 NIGHT MODE LAMP OF KomVision MONITOR IS ABNORMAL.........................................................................................3950 KomVision MONITOR DOES NOT DISPLAY CAMERA IMAGE PARTIALLY................................................................................3954 KomVision MONITOR DOES NOT DISPLAY NORMALLY AFTER CALIBRATION............................................................................3956 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)................................................................................3958 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (H MODE)..................................................................................3958 FAILURE MODE AND CAUSE TABLE.............................................................................................................3959 MACHINE DOES NOT MOVE....................................................................................................................3973 ECMV OPERATION TABLE.................................................................................................................3981 TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADEABILITY IS LOW, OR GEAR DOES NOT SHIFT...........................................3982 ECMV OPERATION TABLE.................................................................................................................3989 STRONG SHOCKS ARE MADE WHEN YOU START MACHINE OR SHIFT GEARS.............................................................................3990 ECMV OPERATION TABLE.................................................................................................................3995 TIME LAG IS LARGE WHEN YOU START MACHINE OR SHIFT GEARS..................................................................................3996 ECMV OPERATION TABLE.................................................................................................................4001 TORQUE CONVERTER OIL TEMPERATURE IS HIGH.................................................................................................4002 MACHINE DOES NOT TURN....................................................................................................................4008 TURNING RESPONSE IS POOR.................................................................................................................4014 MACHINE SWAYS OR STRONG SHOCKS ARE MADE WHILE MACHINE TURNS..............................................................................4020 WHEEL BRAKES DO NOT WORK OR ARE WEAK.....................................................................................................4025 WHEEL BRAKES ARE NOT RELEASED OR DRAG....................................................................................................4029 PARKING BRAKE DOES NOT WORK OR IS WEAK...................................................................................................4031 PARKING BRAKE IS NOT RELEASED OR DRAGS...................................................................................................4033 BOOM DOES NOT RISE.......................................................................................................................4037 BOOM MOVES SLOW OR LACKS LIFTING FORCE...................................................................................................4043 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT.................................................................................................4049 LIFT CYLINDER DOES NOT HOLD BUCKET ON GROUND.............................................................................................4050 HYDRAULIC DRIFT OF BOOM IS LARGE.........................................................................................................4054 BOOM MOVES UP AND DOWN DURING OPERATION..................................................................................................4056 BUCKET DOES NOT TILT BACK................................................................................................................4058 BUCKET MOVES SLOW OR LACKS TILT BACK FORCE...............................................................................................4065 BUCKET SLOWS DOWN DURING TILT BACK OPERATION.............................................................................................4072 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND...........................................................................................4073 HYDRAULIC DRIFT OF BUCKET IS LARGE.......................................................................................................4077 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD.........................................................................................4079 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE................................................................4081 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS WHEN YOU OPERATE WORK EQUIPMENT...............................................................4083 STRONG SHOCKS ARE MADE WHEN YOU MOVE OR STOP WORK EQUIPMENT..............................................................................4087 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES.........................................................4094 ECSS DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES....................................................................................4095 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT MOVE)................................................................................4098 UNUSUAL NOISE IS HEARD FROM AROUND FAN...................................................................................................4102 TROUBLESHOOTING OF ENGINE (S-MODE)...........................................................................................................4103 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (S MODE)..................................................................................4103 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION...................................................................4104 ENGINE CRANKS BUT DOES NOT START.........................................................................................................4106 FUEL IS INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START).................................................4111 ENGINE STARTABILITY IS POOR..............................................................................................................4118 ENGINE DOES NOT PICK UP SMOOTHLY.........................................................................................................4125 ENGINE STOPS DURING OPERATION............................................................................................................4132 ENGINE RUNS ROUGH OR IS UNSTABLE.........................................................................................................4139 ENGINE LACKS POWER.......................................................................................................................4145 KDPF GETS CLOGGED IN A SHORT TIME........................................................................................................4152 ENGINE OIL CONSUMPTION IS EXCESSIVE......................................................................................................4158 OIL BECOMES CONTAMINATED QUICKLY.........................................................................................................4162 FUEL CONSUMPTION IS EXCESSIVE............................................................................................................4166 OIL MIXES INTO COOLANT (OR COOLANT SPURTS BACK AND COOLANT LEVEL DOES DOWN)..............................................................4170 ENGINE OIL PRESSURE DROPS................................................................................................................4172 FUEL MIXES INTO ENGINE OIL...............................................................................................................4176 WATER MIXES INTO ENGINE OIL (MILKY)......................................................................................................4178 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEAT)............................................................................................4181 UNUSUAL NOISE IS HEARD...................................................................................................................4186 VIBRATION IS EXCESSIVE...................................................................................................................4190 AIR CANNOT BE BLED FROM FUEL CIRCUIT.....................................................................................................4193 ACTIVE REGENERATION IS EXECUTED FREQUENTLY...............................................................................................4197 ACTIVE REGENERATION TAKES LONG...........................................................................................................4204 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION......................................................................................4209 50 DISASSEMBLY AND ASSEMBLY......................................................................................................................4211 CONTENTS.....................................................................................................................................4212 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY..............................................................................................4217 HOW TO READ THIS MANUAL..................................................................................................................4217 COATING MATERIALS LIST...................................................................................................................4219 SPECIAL TOOLS LIST.......................................................................................................................4223 SKETCHES OF SPECIAL TOOLS................................................................................................................4240 ENGINE AND COOLING SYSTEM....................................................................................................................4253 REMOVE AND INSTALL COOLING ASSEMBLY......................................................................................................4253 REMOVE COOLING ASSEMBLY..............................................................................................................4255 INSTALL COOLING ASSEMBLY.............................................................................................................4271 REMOVE AND INSTALL RADIATOR CORE.........................................................................................................4289 REMOVE RADIATOR CORE.................................................................................................................4290 INSTALL RADIATOR CORE................................................................................................................4297 REMOVE AND INSTALL RADIATOR RESERVOIR TANK ASSEMBLY......................................................................................4304 REMOVE RADIATOR RESERVOIR TANK ASSEMBLY..............................................................................................4304 INSTALL RADIATOR RESERVOIR TANK ASSEMBLY.............................................................................................4306 REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY....................................................................................4308 REMOVE COOLING FAN AND FAN MOTOR ASSEMBLY............................................................................................4309 INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY...........................................................................................4313 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY.........................................................................................4317 REMOVE HYDRAULIC COOLER ASSEMBLY.....................................................................................................4317 INSTALL HYDRAULIC COOLER ASSEMBLY....................................................................................................4319 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY..................................................................................................4321 REMOVE AFTER COOLER ASSEMBLY.........................................................................................................4322 INSTALL AFTER COOLER ASSEMBLY........................................................................................................4327 REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY.......................................................................................4332 REMOVE POWER TRAIN OIL COOLER ASSEMBLY...............................................................................................4333 INSTALL POWER TRAIN OIL COOLER ASSEMBLY..............................................................................................4334 REMOVE AND INSTALL BRAKE COOLER..........................................................................................................4337 REMOVE BRAKE COOLER..................................................................................................................4337 INSTALL BRAKE COOLER.................................................................................................................4338 REMOVE AND INSTALL ENGINE ASSEMBLY.......................................................................................................4340 REMOVE ENGINE ASSEMBLY...............................................................................................................4342 INSTALL ENGINE ASSEMBLY..............................................................................................................4356 REMOVE AND INSTALL UPPER PORTION OF ENGINE...............................................................................................4371 REMOVE UPPER PORTION OF ENGINE.......................................................................................................4372 INSTALL UPPER PORTION OF ENGINE......................................................................................................4377 REMOVE AND INSTALL TOP HOOD ASSEMBLY.....................................................................................................4382 REMOVE TOP HOOD ASSEMBLY.............................................................................................................4382 INSTALL TOP HOOD ASSEMBLY............................................................................................................4384 REMOVE AND INSTALL FUEL TANK ASSEMBLY....................................................................................................4387 REMOVE FUEL TANK ASSEMBLY............................................................................................................4388 INSTALL FUEL TANK ASSEMBLY...........................................................................................................4394 REMOVE AND INSTALL KDPF ASSEMBLY.........................................................................................................4399 REMOVE KDPF ASSEMBLY.................................................................................................................4400 INSTALL KDPF ASSEMBLY................................................................................................................4406 DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY...................................................................................................4414 DISASSEMBLE KDPF ASSEMBLY............................................................................................................4415 ASSEMBLE KDPF ASSEMBLY...............................................................................................................4421 REMOVE AND INSTALL AIR CLEANER ASSEMBLY..................................................................................................4430 REMOVE AIR CLEANER ASSEMBLY..........................................................................................................4431 INSTALL AIR CLEANER ASSEMBLY.........................................................................................................4432 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY...................................................................................4435 REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY...........................................................................................4436 INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY..........................................................................................4438 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY....................................................................................4441 REMOVE AIR CONDITIONER CONDENSER ASSEMBLY............................................................................................4442 INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...........................................................................................4444 DRAIN AND ADD COOLANT....................................................................................................................4447 DRAIN COOLANT........................................................................................................................4447 ADD COOLANT..........................................................................................................................4449 POWER TRAIN..................................................................................................................................4451 REMOVE AND INSTALL DAMPER ASSEMBLY.......................................................................................................4451 REMOVE DAMPER ASSEMBLY...............................................................................................................4453 INSTALL DAMPER ASSEMBLY..............................................................................................................4455 DISASSEMBLE AND ASSEMBLE DAMPER ASSEMBLY.................................................................................................4458 DISASSEMBLE DAMPER ASSEMBLY..........................................................................................................4459 ASSEMBLE DAMPER ASSEMBLY.............................................................................................................4460 REMOVE AND INSTALL TRANSMISSION, TRANSFER ASSEMBLY AND TORQUE CONVERTER, INPUT TRANSFER, PTO ASSEMBLY....................................4466 REMOVE TRANSMISSION, TRANSFER ASSEMBLY AND TORQUE CONVERTER, INPUT TRANSFER, PTO ASSEMBLY............................................4470 INSTALL TRANSMISSION, TRANSFER ASSEMBLY AND TORQUE CONVERTER, INPUT TRANSFER, PTO ASSEMBLY...........................................4495 DISCONNECT AND CONNECT TRANSMISSION, TRANSFER ASSEMBLY AND TORQUE CONVERTER, INPUT TRANSFER, PTO ASSEMBLY................................4521 DISCONNECT TRANSMISSION, TRANSFER ASSEMBLY AND TORQUE CONVERTER, INPUT TRANSFER, PTO ASSEMBLY........................................4522 CONNECT TRANSMISSION, TRANSFER ASSEMBLY AND TORQUE CONVERTER, INPUT TRANSFER, PTO ASSEMBLY...........................................4527 DISCONNECT AND CONNECT TORQUE CONVERTER, INPUT TRANSFER AND PTO ASSEMBLY.................................................................4535 DISCONNECT TORQUE CONVERTER, INPUT TRANSFER, PTO ASSEMBLY............................................................................4536 CONNECT TORQUE CONVERTER, INPUT TRANSFER, PTO ASSEMBLY...............................................................................4538 DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY.......................................................................................4541 DISASSEMBLE TORQUE CONVERTER ASSEMBLY................................................................................................4542 ASSEMBLE TORQUE CONVERTER ASSEMBLY...................................................................................................4544 DISASSEMBLE AND ASSEMBLE INPUT TRANSFER AND PTO ASSEMBLY.................................................................................4549 DISASSEMBLE INPUT TRANSFER AND PTO ASSEMBLY..........................................................................................4551 ASSEMBLE INPUT TRANSFER AND PTO ASSEMBLY.............................................................................................4562 DISCONNECT AND CONNECT TRANSMISSION AND TRANSFER ASSEMBLY................................................................................4584 DISCONNECT TRANSMISSION AND TRANSFER ASSEMBLY........................................................................................4584 CONNECT TRANSMISSION AND TRANSFER ASSEMBLY...........................................................................................4585 DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY...........................................................................................4587 DISASSEMBLE TRANSMISSION ASSEMBLY....................................................................................................4589 ASSEMBLE TRANSMISSION ASSEMBLY.......................................................................................................4602 DISASSEMBLE AND ASSEMBLE TRANSFER ASSEMBLY...............................................................................................4617 DISASSEMBLE TRANSFER ASSEMBLY........................................................................................................4619 ASSEMBLE TRANSFER ASSEMBLY...........................................................................................................4627 REMOVE AND INSTALL PARKING BRAKE ASSEMBLY................................................................................................4641 REMOVE PARKING BRAKE ASSEMBLY........................................................................................................4642 INSTALL PARKING BRAKE ASSEMBLY.......................................................................................................4646 DISASSEMBLE AND ASSEMBLE PARKING BRAKE ASSEMBLY..........................................................................................4649 DISASSEMBLE PARKING BRAKE ASSEMBLY...................................................................................................4650 ASSEMBLE PARKING BRAKE ASSEMBLY......................................................................................................4652 DRAIN AND ADD TRANSMISSION OIL...........................................................................................................4656 DRAIN TRANSMISSION OIL...............................................................................................................4656 ADD TRANSMISSION OIL.................................................................................................................4657 REMOVE AND INSTALL FRONT AXLE ASSEMBLY...................................................................................................4658 REMOVE FRONT AXLE ASSEMBLY...........................................................................................................4660 INSTALL FRONT AXLE ASSEMBLY..........................................................................................................4667 REMOVE AND INSTALL REAR AXLE ASSEMBLY....................................................................................................4673 REMOVE REAR AXLE ASSEMBLY............................................................................................................4675 INSTALL REAR AXLE ASSEMBLY...........................................................................................................4683 REMOVE AND INSTALL CENTER SUPPORT ASSEMBLY...............................................................................................4691 REMOVE CENTER SUPPORT ASSEMBLY.......................................................................................................4692 INSTALL CENTER SUPPORT ASSEMBLY......................................................................................................4694 DISASSEMBLE AND ASSEMBLE CENTER SUPPORT ASSEMBLY.........................................................................................4698 DISASSEMBLE CENTER SUPPORT ASSEMBLY..................................................................................................4698 ASSEMBLE CENTER SUPPORT ASSEMBLY.....................................................................................................4700 REMOVE AND INSTALL DIFFERENTIAL ASSEMBLY.................................................................................................4705 REMOVE DIFFERENTIAL ASSEMBLY.........................................................................................................4706 INSTALL DIFFERENTIAL ASSEMBLY........................................................................................................4709 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY...........................................................................................4713 DISASSEMBLE DIFFERENTIAL ASSEMBLY....................................................................................................4715 ASSEMBLE DIFFERENTIAL ASSEMBLY.......................................................................................................4725 REMOVE AND INSTALL FINAL DRIVE CARRIER ASSEMBLY..........................................................................................4747 REMOVE FINAL DRIVE CARRIER ASSEMBLY..................................................................................................4748 INSTALL FINAL DRIVE CARRIER ASSEMBLY.................................................................................................4749 DISASSEMBLE AND ASSEMBLE FINAL DRIVE CARRIER ASSEMBLY....................................................................................4752 DISASSEMBLE FINAL DRIVE CARRIER ASSEMBLY.............................................................................................4752 ASSEMBLE FINAL DRIVE CARRIER ASSEMBLY................................................................................................4754 REMOVE AND INSTALL FRONT FINAL DRIVE AND BRAKE ASSEMBLY..................................................................................4757 REMOVE FRONT FINAL DRIVE AND BRAKE ASSEMBLY..........................................................................................4757 INSTALL FRONT FINAL DRIVE AND BRAKE ASSEMBLY.........................................................................................4761 DISASSEMBLE AND ASSEMBLE FINAL DRIVE AND BRAKE ASSEMBLY..................................................................................4765 DISASSEMBLE FINAL DRIVE AND BRAKE ASSEMBLY...........................................................................................4767 ASSEMBLE FINAL DRIVE AND BRAKE ASSEMBLY..............................................................................................4776 STEERING SYSTEM..............................................................................................................................4793 REMOVE AND INSTALL STEERING VALVE ASSEMBLY...............................................................................................4793 REMOVE STEERING VALVE ASSEMBLY.......................................................................................................4794 INSTALL STEERING VALVE ASSEMBLY......................................................................................................4802 REMOVE AND INSTALL ROTARY VALVE ASSEMBLY.................................................................................................4811 REMOVE ROTARY VALVE ASSEMBLY.........................................................................................................4812 INSTALL ROTARY VALVE ASSEMBLY........................................................................................................4814 BRAKE SYSTEM.................................................................................................................................4817 REMOVE AND INSTALL RIGHT BRAKE VALVE ASSEMBLY............................................................................................4817 REMOVE RIGHT BRAKE VALVE ASSEMBLY....................................................................................................4818 INSTALL RIGHT BRAKE VALVE ASSEMBLY...................................................................................................4821 REMOVE AND INSTALL LEFT BRAKE VALVE ASSEMBLY.............................................................................................4826 REMOVE LEFT BRAKE VALVE ASSEMBLY.....................................................................................................4827 INSTALL LEFT BRAKE VALVE ASSEMBLY....................................................................................................4829 REMOVE AND INSTALL BRAKE ACCUMULATOR ASSEMBLY............................................................................................4833 REMOVE BRAKE ACCUMULATOR ASSEMBLY....................................................................................................4834 INSTALL BRAKE ACCUMULATOR ASSEMBLY...................................................................................................4837 UNDERCARRIAGE AND FRAME......................................................................................................................4840 REMOVE AND INSTALL CENTER HINGE PIN......................................................................................................4840 REMOVE CENTER HINGE PIN..............................................................................................................4844 INSTALL CENTER HINGE PIN.............................................................................................................4855 REMOVE AND INSTALL BUMPER ASSEMBLY.......................................................................................................4873 REMOVE BUMPER ASSEMBLY...............................................................................................................4874 INSTALL BUMPER ASSEMBLY..............................................................................................................4877 HYDRAULIC SYSTEM.............................................................................................................................4880 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...............................................................................................4880 REMOVE HYDRAULIC TANK ASSEMBLY.......................................................................................................4881 INSTALL HYDRAULIC TANK ASSEMBLY......................................................................................................4889 REMOVE AND INSTALL WORK EQUIPMENT PUMP, PILOT AND BRAKE CHARGE PUMP ASSEMBLY.............................................................4896 REMOVE WORK EQUIPMENT PUMP, PILOT AND BRAKE CHARGE PUMP ASSEMBLY.....................................................................4897 INSTALL WORK EQUIPMENT PUMP, PILOT AND BRAKE CHARGE PUMP ASSEMBLY....................................................................4902 REMOVE AND INSTALL WORK EQUIPMENT PUMP AND BRAKE COOLING DUPLEX PUMP ASSEMBLY............................................................4906 REMOVE WORK EQUIPMENT PUMP AND BRAKE COOLING DUPLEX PUMP ASSEMBLY....................................................................4907 INSTALL WORK EQUIPMENT PUMP AND BRAKE COOLING DUPLEX PUMP ASSEMBLY...................................................................4911 REMOVE AND INSTALL SECONDARY STEERING PUMP ASSEMBLY......................................................................................4915 REMOVE SECONDARY STEERING PUMP ASSEMBLY..............................................................................................4916 INSTALL SECONDARY STEERING PUMP ASSEMBLY.............................................................................................4917 REMOVE AND INSTALL STEERING PUMP ASSEMBLY................................................................................................4919 REMOVE STEERING PUMP ASSEMBLY........................................................................................................4920 INSTALL STEERING PUMP ASSEMBLY.......................................................................................................4926 REMOVE AND INSTALL COOLING PUMP AND COOLING FAN PUMP ASSEMBLY............................................................................4931 REMOVE COOLING PUMP AND COOLING FAN PUMP ASSEMBLY....................................................................................4932 INSTALL COOLING PUMP AND COOLING FAN PUMP ASSEMBLY...................................................................................4937 REMOVE AND INSTALL TRANSMISSION AND TORQUE CONVERTER LUBRICATION TRIPLEX PUMP ASSEMBLY...................................................4943 REMOVE TRANSMISSION AND TORQUE CONVERTER LUBRICATION TRIPLEX PUMP ASSEMBLY...........................................................4944 INSTALL TRANSMISSION AND TORQUE CONVERTER LUBRICATION TRIPLEX PUMP ASSEMBLY..........................................................4946 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY................................................................................................4948 REMOVE CONTROL VALVE ASSEMBLY........................................................................................................4949 INSTALL CONTROL VALVE ASSEMBLY.......................................................................................................4961 REMOVE AND INSTALL DIVERTER VALVE ASSEMBLY...............................................................................................4973 REMOVE DIVERTER VALVE ASSEMBLY.......................................................................................................4974 INSTALL DIVERTER VALVE ASSEMBLY......................................................................................................4977 DRAIN AND ADD HYDRAULIC OIL..............................................................................................................4980 DRAIN HYDRAULIC OIL..................................................................................................................4980 ADD HYDRAULIC OIL....................................................................................................................4982 WORK EQUIPMENT...............................................................................................................................4983 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY...............................................................................................4983 REMOVE WORK EQUIPMENT ASSEMBLY.......................................................................................................4984 INSTALL WORK EQUIPMENT ASSEMBLY......................................................................................................4991 DISASSEMBLE AND ASSEMBLE STEERING CYLINDER ASSEMBLY......................................................................................4999 DISASSEMBLE STEERING CYLINDER ASSEMBLY...............................................................................................5000 ASSEMBLE STEERING CYLINDER ASSEMBLY..................................................................................................5002 DISASSEMBLE AND ASSEMBLE BUCKET CYLINDER ASSEMBLY........................................................................................5006 DISASSEMBLE BUCKET CYLINDER ASSEMBLY.................................................................................................5007 ASSEMBLE BUCKET CYLINDER ASSEMBLY....................................................................................................5009 DISASSEMBLE AND ASSEMBLE LIFT CYLINDER ASSEMBLY..........................................................................................5013 DISASSEMBLE LIFT CYLINDER ASSEMBLY...................................................................................................5014 ASSEMBLE LIFT CYLINDER ASSEMBLY......................................................................................................5016 REMOVE AND INSTALL BOOM END (BUCKET HINGE) BUSHING.......................................................................................5020 REMOVE BOOM END (BUCKET HINGE) BUSHING...............................................................................................5020 INSTALL BOOM END (BUCKET HINGE) BUSHING..............................................................................................5021 CAB RELATED PARTS............................................................................................................................5022 REMOVE AND INSTALL ROPS ASSEMBLY.........................................................................................................5022 REMOVE ROPS ASSEMBLY.................................................................................................................5023 INSTALL ROPS ASSEMBLY................................................................................................................5027 REMOVE AND INSTALL OPERATOR CAB ASSEMBLY AND FLOOR FRAME ASSEMBLY........................................................................5032 REMOVE OPERATOR CAB ASSEMBLY AND FLOOR FRAME ASSEMBLY................................................................................5034 INSTALL OPERATOR CAB ASSEMBLY AND FLOOR FRAME ASSEMBLY...............................................................................5044 REMOVE AND INSTALL OPERATOR CAB ASSEMBLY.................................................................................................5055 REMOVE OPERATOR CAB ASSEMBLY.........................................................................................................5056 INSTALL OPERATOR CAB ASSEMBLY........................................................................................................5070 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)....................................................................................5084 REMOVE OPERATOR CAB GLASS (ADHERED GLASS)............................................................................................5084 INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...........................................................................................5085 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY.........................................................................................5094 REMOVE AIR CONDITIONER UNIT ASSEMBLY.................................................................................................5095 INSTALL AIR CONDITIONER UNIT ASSEMBLY................................................................................................5101 REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY..............................................................................................5109 REMOVE OPERATOR SEAT ASSEMBLY........................................................................................................5109 INSTALL OPERATOR SEAT ASSEMBLY.......................................................................................................5112 REMOVE AND INSTALL WORK EQUIPMENT CONTROL LEVER..........................................................................................5116 REMOVE WORK EQUIPMENT CONTROL LEVER..................................................................................................5116 INSTALL WORK EQUIPMENT CONTROL LEVER.................................................................................................5120 REMOVE AND INSTALL SEATBELT..............................................................................................................5124 REMOVE SEATBELT......................................................................................................................5124 INSTALL SEATBELT.....................................................................................................................5125 REMOVE AND INSTALL AJSS LEVER SWITCH ASSEMBLY............................................................................................5127 REMOVE AJSS LEVER SWITCH ASSEMBLY....................................................................................................5128 INSTALL AJSS LEVER SWITCH ASSEMBLY...................................................................................................5132 ELECTRICAL SYSTEM............................................................................................................................5138 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY............................................................................................5138 REMOVE ENGINE CONTROLLER ASSEMBLY....................................................................................................5138 INSTALL ENGINE CONTROLLER ASSEMBLY...................................................................................................5142 REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY....................................................................................5148 REMOVE WORK EQUIPMENT CONTROLLER ASSEMBLY............................................................................................5148 INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY...........................................................................................5151 REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY......................................................................................5154 REMOVE TRANSMISSION CONTROLLER ASSEMBLY..............................................................................................5154 INSTALL TRANSMISSION CONTROLLER ASSEMBLY.............................................................................................5157 REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY...........................................................................................5160 REMOVE MONITOR CONTROLLER ASSEMBLY...................................................................................................5160 INSTALL MONITOR CONTROLLER ASSEMBLY..................................................................................................5163 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY..............................................................................................5166 REMOVE MACHINE MONITOR ASSEMBLY......................................................................................................5166 INSTALL MACHINE MONITOR ASSEMBLY.....................................................................................................5168 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR..................................................................................5171 REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR..........................................................................................5171 INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR.........................................................................................5172 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR........................................................................................5173 REMOVE KCCV CRANKCASE PRESSURE SENSOR................................................................................................5173 INSTALL KCCV CRANKCASE PRESSURE SENSOR...............................................................................................5176 REMOVE AND INSTALL KDPF TEMPERATURE SENSOR...............................................................................................5180 REMOVE KDPF TEMPERATURE SENSOR.......................................................................................................5180 INSTALL KDPF TEMPERATURE SENSOR......................................................................................................5187 REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR.....................................................................................5192 REMOVE KDPF DIFFERENTIAL PRESSURE SENSOR.............................................................................................5192 INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR............................................................................................5195 REMOVE AND INSTALL KomVision CAMERA ASSEMBLY.............................................................................................5199 REMOVE KomVision CAMERA ASSEMBLY.....................................................................................................5201 INSTALL KomVision CAMERA ASSEMBLY....................................................................................................5211 REMOVE AND INSTALL KomVision RADAR ASSEMBLY..............................................................................................5222 REMOVE KomVision RADAR ASSEMBLY......................................................................................................5224 INSTALL KomVision RADAR ASSEMBLY.....................................................................................................5227 REMOVE AND INSTALL KomVision CONTROLLER..................................................................................................5230 REMOVE KomVision CONTROLLER..........................................................................................................5230 INSTALL KomVision CONTROLLER.........................................................................................................5231 REMOVE AND INSTALL KOMTRAX Plus CONTROLLER ASSEMBLY......................................................................................5233 REMOVE KOMTRAX Plus CONTROLLER ASSEMBLY..............................................................................................5233 INSTALL KOMTRAX Plus CONTROLLER ASSEMBLY.............................................................................................5235 REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY............................................................................................5237 REMOVE WIRELESS LAN UNIT ASSEMBLY....................................................................................................5237 INSTALL WIRELESS LAN UNIT ASSEMBLY...................................................................................................5239 60 MAINTENANCE STANDARD..........................................................................................................................5241 CONTENTS.....................................................................................................................................5242 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD................................................................................................5243 ENGINE AND COOLING SYSTEM....................................................................................................................5245 MAINTENANCE STANDARD OF ENGINE MOUNT.....................................................................................................5245 MAINTENANCE STANDARD OF DAMPER...........................................................................................................5246 MAINTENANCE STANDARD OF COOLING FAN PUMP.................................................................................................5248 SERVO VALVE OF COOLING FAN PUMP......................................................................................................5250 MAINTENANCE STANDARD OF COOLING FAN MOTOR................................................................................................5251 POWER TRAIN..................................................................................................................................5254 MAINTENANCE STANDARD OF DRIVE SHAFT......................................................................................................5254 MAINTENANCE STANDARD OF CENTER SUPPORT...................................................................................................5255 MAINTENANCE STANDARD OF TRANSMISSION MOUNT...............................................................................................5257 MAINTENANCE STANDARD OF TORQUE FLOW ASSEMBLY.............................................................................................5259 MAINTENANCE STANDARD OF TORQUE CONVERTER.................................................................................................5261 MAINTENANCE STANDARD OF MODULATION CLUTCH................................................................................................5268 MAINTENANCE STANDARD OF VALVE ASSEMBLY (FOR MAIN RELIEF AND TORQUE CONVERTER RELIEF).....................................................5270 MAINTENANCE STANDARD OF TORQUE CONVERTER REGULATOR VALVE.................................................................................5272 MAINTENANCE STANDARD OF TRANSMISSION.....................................................................................................5274 MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE.......................................................................................5282 MAINTENANCE STANDARD OF F, R, 1ST, 2ND, 3RD CLUTCH ECMV..................................................................................5283 MAINTENANCE STANDARD OF MODULATION CLUTCH ECMV...........................................................................................5285 MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION RELIEF VALVE............................................................................5287 MAINTENANCE STANDARD OF FRONT AXLE.......................................................................................................5288 MAINTENANCE STANDARD OF REAR AXLE........................................................................................................5290 MAINTENANCE STANDARD OF FRONT DIFFERENTIAL...............................................................................................5292 MAINTENANCE STANDARD OF REAR DIFFERENTIAL................................................................................................5296 MAINTENANCE STANDARD OF FINAL DRIVE......................................................................................................5300 STEERING SYSTEM..............................................................................................................................5302 MAINTENANCE STANDARD OF STEERING PUMP....................................................................................................5302 MAINTENANCE STANDARD OF STEERING CYLINDER................................................................................................5305 BRAKE SYSTEM.................................................................................................................................5307 MAINTENANCE STANDARD OF BRAKE............................................................................................................5307 MAINTENANCE STANDARD OF PARKING BRAKE....................................................................................................5309 MAINTENANCE STANDARD OF PARKING BRAKE CIRCUIT CHECK VALVE................................................................................5311 UNDERCARRIAGE AND FRAME......................................................................................................................5312 MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN...........................................................................5312 HYDRAULIC SYSTEM.............................................................................................................................5319 MAINTENANCE STANDARD OF HYDRAULIC TANK...................................................................................................5319 MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP..............................................................................................5321 MAINTENANCE STANDARD OF CONTROL VALVE....................................................................................................5324 WORK EQUIPMENT...............................................................................................................................5337 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE...........................................................................................5337 MAINTENANCE STANDARD OF BUCKET...........................................................................................................5341 MAINTENANCE STANDARD OF LIFT CYLINDER....................................................................................................5342 MAINTENANCE STANDARD OF BUCKET CYLINDER..................................................................................................5343 CAB RELATED PARTS............................................................................................................................5344 MAINTENANCE STANDARD OF CAB MOUNT........................................................................................................5344 80 OTHERS........................................................................................................................................5345 CONTENTS.....................................................................................................................................5346 AIR CONDITIONER SYSTEM.......................................................................................................................5348 PRECAUTIONS FOR REFRIGERANT..............................................................................................................5348 AIR CONDITIONER..........................................................................................................................5349 SPECIFICATIONS OF AIR CONDITIONER........................................................................................................5351 STRUCTURE AND FUNCTION OF REFRIGERATION CYCLE............................................................................................5352 OUTLINE OF REFRIGERATION CYCLE...........................................................................................................5353 COMPONENT PARTS OF AIR CONDITIONER SYSTEM................................................................................................5355 AIR CONDITIONER UNIT.................................................................................................................5355 AIR CONDITIONER UNIT.....................................................................................................................5358 FUNCTION OF EVAPORATOR...............................................................................................................5358 FUNCTION OF HEATER CORE..............................................................................................................5358 FUNCTION OF EVAPORATOR TEMPERATURE SENSOR............................................................................................5358 FUNCTION OF SERVOMOTOR...............................................................................................................5358 STRUCTURE OF EXPANSION VALVE.........................................................................................................5359 FUNCTION OF EXPANSION VALVE..........................................................................................................5359 OPERATION OF EXPANSION VALVE.........................................................................................................5359 FUNCTION OF TRIPLE PRESSURE SWITCH...................................................................................................5360 AIR CONDITIONER CONTROLLER...............................................................................................................5362 STRUCTURE OF AIR CONDITIONER CONTROLLER..............................................................................................5362 COMPRESSOR...............................................................................................................................5363 STRUCTURE OF COMPRESSOR..............................................................................................................5363 SPECIFICATIONS OF COMPRESSOR.........................................................................................................5363 FUNCTION OF COMPRESSOR...............................................................................................................5363 CONDENSER................................................................................................................................5365 STRUCTURE OF CONDENSER...............................................................................................................5365 SPECIFICATIONS OF CONDENSER..........................................................................................................5365 FUNCTION OF CONDENSER................................................................................................................5365 RECEIVER DRIER...........................................................................................................................5367 STRUCTURE OF RECEIVER DRIER..........................................................................................................5367 SPECIFICATIONS OF RECEIVER DRIER.....................................................................................................5367 FUNCTION OF RECEIVER DRIER...........................................................................................................5367 AIR CONDITIONER RELATED SENSORS..........................................................................................................5368 STRUCTURE OF SUNLIGHT SENSOR.........................................................................................................5368 FUNCTION OF SUNLIGHT SENSOR..........................................................................................................5368 STRUCTURE OF AMBIENT TEMPERATURE SENSOR..............................................................................................5368 FUNCTION OF AMBIENT TEMPERATURE SENSOR...............................................................................................5368 PROCEDURE FOR TESTING AND TROUBLESHOOTING AIR CONDITIONER................................................................................5369 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER....................................................................5371 AIR CONDITIONER SYSTEM DIAGRAM...........................................................................................................5373 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER...................................................................................5374 FUNCTION OF AIR CONDITIONER CONTROLLER...............................................................................................5375 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS............................................................5376 TEST AIR LEAKAGE (DUCT)..................................................................................................................5380 TEST AIR LEAKAGE (DUCT)..............................................................................................................5380 TEST AIR CONDITIONER WITH SELF-DIAGNOSIS FUNCTION........................................................................................5382 OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF MACHINE MONITOR..............................................5383 TEST VENT (MODE) CHANGEOVER..............................................................................................................5384 TEST VENT (MODE) CHANGEOVER..........................................................................................................5384 TEST FRESH/RECIRC AIR CHANGEOVER.........................................................................................................5385 TEST FRESH/RECIRC AIR CHANGEOVER.....................................................................................................5385 TEST SUNLIGHT SENSOR.....................................................................................................................5386 TEST SUNLIGHT SENSOR.................................................................................................................5386 TEST (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT............................................................................................5387 METHOD FOR TESTING (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT..........................................................................5387 TEST RELAYS..............................................................................................................................5389 TEST RELAYS..........................................................................................................................5389 AIR CONDITIONER TROUBLESHOOTING CHART 1..................................................................................................5390 AIR CONDITIONER TROUBLESHOOTING CHART 2..................................................................................................5392 INFORMATION DESCRIBED IN TROUBLESHOOTING.................................................................................................5395 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)........................................................................................5398 FAILURE CODE [879AKA]................................................................................................................5398 FAILURE CODE [879AKB]................................................................................................................5399 FAILURE CODE [879BKA]................................................................................................................5400 FAILURE CODE [879BKB]................................................................................................................5403 FAILURE CODE [879CKA]................................................................................................................5406 FAILURE CODE [879CKB]................................................................................................................5407 FAILURE CODE [879DKZ]................................................................................................................5408 FAILURE CODE [879EMC]................................................................................................................5412 FAILURE CODE [879FMC]................................................................................................................5413 FAILURE CODE [879GKX]................................................................................................................5414 TROUBLESHOOTING OF AIR CONDITIONER SYSTEM (A-MODE).......................................................................................5417 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)...........................................................5417 TROUBLESHOOTING FOR CONDENSER........................................................................................................5422 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)............................................................5429 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)...................................................5434 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER......................................................................................5438 TROUBLESHOOTING BY GAUGE PRESSURE....................................................................................................5441 CONNECT SERVICE TOOL.....................................................................................................................5445 CONNECT SERVICE TOOL.................................................................................................................5445 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF AIR CONDITIONER PIPINGS..............................................................5446 COMPRESSOR OIL.......................................................................................................................5447 KomVision SYSTEM.............................................................................................................................5449 STRUCTURE AND OPERATION OF KomVision SYSTEM..............................................................................................5449 PRECAUTIONS FOR KomVision SYSTEM.....................................................................................................5449 LAYOUT DRAWING OF KomVision SYSTEM...................................................................................................5450 KomVision SYSTEM.....................................................................................................................5456 TEST AND ADJUST KomVision SYSTEM.........................................................................................................5469 SETTING AND OPERATION OF KomVision MONITOR...........................................................................................5469 CAMERA CALIBRATION.......................................................................................................................5489 5 CAMERA CALIBRATION.................................................................................................................5490 1 CAMERA CALIBRATION.................................................................................................................5515 ADJUST RADAR (FOR MACHINE WITH RADAR)....................................................................................................5522 SET DEFAULT RADAR SETTING............................................................................................................5522 ADJUST RADAR.........................................................................................................................5524 TROUBLESHOOTING FOR KomVision SYSTEM.....................................................................................................5529 RELATED INFORMATION TO TROUBLESHOOT..................................................................................................5529 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)....................................................................................5547 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)........................................................................................5726 90 CIRCUIT DIAGRAMS..............................................................................................................................5753 CONTENTS.....................................................................................................................................5754 HOW TO READ THE CODES FOR ELECTRIC CABLE.....................................................................................................5756 HYDRAULIC CIRCUIT DIAGRAM....................................................................................................................5760 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM................................................................................................5760 HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT.............................................................................................5765 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM....................................................................................................5767 HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT (COMBINATION OF FORWARD 1ST TRAVEL, BOOM RAISE AND BUCKET TILT OPERATION 1/2)...............5769 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN (COMBINATION OF FORWARD 1ST TRAVEL, BOOM RAISE AND BUCKET TILT OPERATION 2/2)..................5771 HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT(COMBINATION OF BOOM LOWER, REVERSE 2ND TRAVEL, STEER LEFT, AND LEFT BRAKE OPERATION 1/2)....5773 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN(COMBINATION OF BOOM LOWER, REVERSE 2ND TRAVEL, STEER LEFT, AND LEFT BRAKE OPERATION 2/2).......5775 ELECTRICAL CIRCUIT DIAGRAM...................................................................................................................5777 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM...............................................................................................5777 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/8)..............................................................................................5781 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/8)..............................................................................................5783 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/8)..............................................................................................5785 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/8)..............................................................................................5787 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/8)..............................................................................................5789 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/8)..............................................................................................5791 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/8)..............................................................................................5793 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/8)..............................................................................................5795 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (1/8)................................................................................................5797 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (2/8)................................................................................................5799 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (3/8)................................................................................................5801 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (4/8)................................................................................................5803 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (5/8)................................................................................................5805 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (6/8)................................................................................................5807 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (7/8)................................................................................................5809 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (8/8)................................................................................................5811 ELECTRICAL CIRCUIT DIAGRAM OF ENGINE (1/2)...............................................................................................5813 ELECTRICAL CIRCUIT DIAGRAM OF ENGINE (2/2)...............................................................................................5815 CONNECTOR AND WIRING HARNESS CHART...........................................................................................................5817 CONNECTOR AND WIRING HARNESS CHART (1/53)................................................................................................5819 CONNECTOR AND WIRING HARNESS CHART (2/53)................................................................................................5821 CONNECTOR AND WIRING HARNESS CHART (3/53)................................................................................................5823 CONNECTOR AND WIRING HARNESS CHART (4/53)................................................................................................5825 CONNECTOR AND WIRING HARNESS CHART (5/53)................................................................................................5827 CONNECTOR AND WIRING HARNESS CHART (6/53)................................................................................................5829 CONNECTOR AND WIRING HARNESS CHART (7/53)................................................................................................5831 CONNECTOR AND WIRING HARNESS CHART (8/53)................................................................................................5833 CONNECTOR AND WIRING HARNESS CHART (9/53)................................................................................................5835 CONNECTOR AND WIRING HARNESS CHART (10/53)...............................................................................................5837 CONNECTOR AND WIRING HARNESS CHART (11/53)...............................................................................................5839 CONNECTOR AND WIRING HARNESS CHART (12/53)...............................................................................................5841 CONNECTOR AND WIRING HARNESS CHART (13/53)...............................................................................................5843 CONNECTOR AND WIRING HARNESS CHART (14/53)...............................................................................................5845 CONNECTOR AND WIRING HARNESS CHART (15/53)...............................................................................................5847 CONNECTOR AND WIRING HARNESS CHART (16/53)...............................................................................................5849 CONNECTOR AND WIRING HARNESS CHART (17/53)...............................................................................................5851 CONNECTOR AND WIRING HARNESS CHART (18/53)...............................................................................................5853 CONNECTOR AND WIRING HARNESS CHART (19/53)...............................................................................................5855 CONNECTOR AND WIRING HARNESS CHART (20/53)...............................................................................................5857 CONNECTOR AND WIRING HARNESS CHART (21/53)...............................................................................................5859 CONNECTOR AND WIRING HARNESS CHART (22/53)...............................................................................................5861 CONNECTOR AND WIRING HARNESS CHART (23/53)...............................................................................................5863 CONNECTOR AND WIRING HARNESS CHART (24/53)...............................................................................................5865 CONNECTOR AND WIRING HARNESS CHART (25/53)...............................................................................................5867 CONNECTOR AND WIRING HARNESS CHART (26/53)...............................................................................................5869 CONNECTOR AND WIRING HARNESS CHART (27/53)...............................................................................................5871 CONNECTOR AND WIRING HARNESS CHART (28/53)...............................................................................................5873 CONNECTOR AND WIRING HARNESS CHART (29/53)...............................................................................................5875 CONNECTOR AND WIRING HARNESS CHART (30/53)...............................................................................................5877 CONNECTOR AND WIRING HARNESS CHART (31/53)...............................................................................................5879 CONNECTOR AND WIRING HARNESS CHART (32/53)...............................................................................................5881 CONNECTOR AND WIRING HARNESS CHART (33/53)...............................................................................................5883 CONNECTOR AND WIRING HARNESS CHART (33/53)...............................................................................................5885 CONNECTOR AND WIRING HARNESS CHART (34/53)...............................................................................................5887 CONNECTOR AND WIRING HARNESS CHART (35/53)...............................................................................................5889 CONNECTOR AND WIRING HARNESS CHART (36/53)...............................................................................................5891 CONNECTOR AND WIRING HARNESS CHART (37/53)...............................................................................................5893 CONNECTOR AND WIRING HARNESS CHART (38/53)...............................................................................................5895 CONNECTOR AND WIRING HARNESS CHART (39/53)...............................................................................................5897 CONNECTOR AND WIRING HARNESS CHART (40/53)...............................................................................................5899 CONNECTOR AND WIRING HARNESS CHART (41/53)...............................................................................................5901 CONNECTOR AND WIRING HARNESS CHART (42/53)...............................................................................................5903 CONNECTOR AND WIRING HARNESS CHART (43/53)...............................................................................................5905 CONNECTOR AND WIRING HARNESS CHART (44/53)...............................................................................................5907 CONNECTOR AND WIRING HARNESS CHART (45/53)...............................................................................................5909 CONNECTOR AND WIRING HARNESS CHART (46/53)...............................................................................................5911 CONNECTOR AND WIRING HARNESS CHART (47/53)...............................................................................................5913 CONNECTOR AND WIRING HARNESS CHART (48/53)...............................................................................................5915 CONNECTOR AND WIRING HARNESS CHART (49/53)...............................................................................................5917 CONNECTOR AND WIRING HARNESS CHART (50/53)...............................................................................................5919 CONNECTOR AND WIRING HARNESS CHART (51/53)...............................................................................................5921 CONNECTOR AND WIRING HARNESS CHART (52/53)...............................................................................................5923 CONNECTOR AND WIRING HARNESS CHART (53/53)...............................................................................................5925 INDEX.............................................................................................................................................5927
DESCRIPTION:
KOMATSU WA900-8 WHEEL LOADER SHOP MANUAL SEN06740-04 – 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 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.S 31/12/24
