Komatsu WHEEL LOADER WA470-8 Shop Manual SEN06514-21 PDF
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Komatsu WHEEL LOADER WA470-8 Shop Manual SEN06514-21 – PDF DOWNLOAD
SERIAL NUMBERS 100001 and up
Description
Komatsu WHEEL LOADER WA470-8 Shop Manual SEN06514-21 – PDF DOWNLOAD
FILE DETAILS:
Komatsu WHEEL LOADER WA470-8 Shop Manual SEN06514-21 – PDF DOWNLOAD
Language : English
Pages :4668
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:’
Komatsu WHEEL LOADER WA470-8 Shop Manual SEN06514-21 – PDF DOWNLOAD
SERIAL NUMBERS 100001 and up
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the
same as the terminology in the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
TABLE OF CONTENTS:
Komatsu WHEEL LOADER WA470-8 Shop Manual SEN06514-21 – PDF DOWNLOAD
SERIAL NUMBERS 100001 and up
Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 27
Foreword, Safety, Basic Information 33
How to Read the Shop Manual 33
Safety Notice for Operation 35
Precautions to Prevent Fire 43
Procedures If Fire Occurs 45
Precautions for Disposing of Waste Materials 46
Procedures for Exhaust Gas Regulations 47
Precautions for DEF 48
General Character and Precautions for Handling 48
Precautions for Adding 48
Precautions for Storage 48
Precautions for Fire Hazard and Leakage 48
Other Precautions 48
Store DEF 49
Precautions When You Handle Hydraulic Equipment 50
Precautions When You Disconnect and Connect Pipings 53
Precautions When You Handle Electrical Equipment 60
Precautions When You Handle Fuel System Equipment 62
Precautions When You Handle Intake System Equipment 63
Practical Use of KOMTRAX 64
Disconnect and Connect Push-Pull Type Coupler 65
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 65
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 66
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 67
Precautions for Disconnection and Connection of Connectors 69
How to Disconnect and Connect Deutsch Connector 73
How to Disconnect and Connect Slide Lock Type Connector 74
How to Disconnect and Connect Connector with Lock to Pull 76
How to Disconnect and Connect Connector with Lock to Push 77
How to Disconnect and Connect Connector with Housing to Rotate 79
How to Read the Codes for Electric Cable 80
Explanation of Terms for Maintenance Standard 84
Standard Tightening Torque Table 87
Conversion Table 94
01 Specifications 99
Table of Contents 100
Abbreviation List 101
Specifications 107
Specification Drawing 107
Specification Drawing: WA470-8 107
Specifications 109
Specifications: WA470-8 109
Weight Table 114
Weight Table: WA470-8 114
Table of Fuel, Coolant, and Lubricants 116
10 Structure and Function 119
Table of Contents 120
Abbreviation List 125
Urea SCR System 131
Layout Drawing of Urea SCR System 131
Urea SCR System Diagram 135
Function of Urea SCR System 136
Function of DEF System 136
Inducement Strategy 139
Component Parts of Urea SCR System 153
DEF Mixing Tube 153
SCR Assembly 154
DEF Tank 156
DEF Pump 158
DEF Injector 159
DEF Hose 160
DEF Tank Heating Valve 161
Boot-up System 162
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) 162
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) 164
System Operating Lamp System 166
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 166
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) 166
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 166
Function of System Operating Lamp System (Machine with Gateway Function Controller) 167
Battery Disconnect Switch 169
Layout Drawing of Battery Disconnect Switch 169
Function of Battery Disconnect Switch 169
Preheating System 171
System Diagram of Preheating System 171
Function of Automatic Preheating System 171
Operation of Automatic Preheating System 171
Function of Manual Preheating System 172
Operation of Manual Preheating System 172
Engine System 173
Layout Drawing of Engine System 173
Function of Engine System 175
Engine Control System 176
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) 176
System Diagram of Engine Control System (Machine with Gateway Function Controller) 177
Function of Engine Control System 177
Operation of Engine Control System 180
Engine Power Mode Selector System 182
Engine Power Mode Selector System Diagram 182
Function of Engine Power Mode Selector System 182
Operation of Engine Power Mode Selector System 182
Automatic Idle Stop System 184
Function of Automatic Idle Stop System 184
Component Parts of Engine System 185
VGT 185
EGR System 189
EGR Valve 191
EGR Cooler 193
KCCV System 194
KCCV Ventilator 196
KDPF 198
Cooling System 202
Layout Drawing of Cooling System 202
Specifications of Cooling System 203
Cooling Fan Control System 205
System Diagram of Cooling Fan Control System 205
Function of Cooling Fan Control System 205
Component Parts of Cooling System 210
Brake and Cooling Fan Pump 210
Cooling Fan Motor 218
Control System 224
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 224
Layout Drawing of Control System (Machine with Gateway Function Controller) 226
Machine Monitor System 228
System Diagram of Machine Monitor System 228
Function of Machine Monitor System 228
Rearview Monitor System 230
System Diagram of Rearview Monitor System 230
Function of Rearview Monitor System 230
KOMTRAX System 231
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 231
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 231
Function of KOMTRAX System 232
RDS Load Meter System 233
Layout Drawing of RDS Load Meter System 233
Function of RDS Load Meter System 234
Component Parts of Control System 235
Machine Monitor 235
Switch Panel 257
Rearview Monitor 258
Rearview Camera 260
KOMTRAX Terminal 261
Gateway Function Controller 263
Communication Terminal 266
Transmission Controller 268
Work Equipment Controller 273
Monitor Controller 278
CAN Terminating Resistor 283
Engine Controller 284
Accelerator Pedal 291
Hydraulic System 293
Layout Drawing of Hydraulic System 293
CLSS 294
Structure of CLSS 294
Function of CLSS 295
Work Equipment Pump and Steering Pump Control System 298
Swash Plate Control Function of Work Equipment Pump and Steering Pump 298
Pickup Assistance Control Function When Engine Speed is Low 298
Overheat Prevention Function of Work Equipment Circuit 298
Component Parts of Hydraulic System 299
Hydraulic Tank 299
Work Equipment Pump 302
Steering Pump 320
Power Train Charge Pump and Power Train Lubrication Pump 333
Control Valve 334
Power Train System 369
Layout Drawing of Power Train System 369
Operation of Power Train System 372
Transmission Control System 373
Transmission Control System Diagram 373
Transmission Gear Shift Control System 375
Electric Modulation Function System Diagram 375
Electric Modulation Function 376
Gear Shift Display Function 376
Automatic Gear Shift Function 376
Shift Hold Function 377
Kickdown Function 377
Automatic Kickdown Function 378
Torque Converter Lockup Function 378
Hunting Prevention Function 379
Transmission Initial Learning and ECMV Current Adjustment Function 379
Shift Point Changing Function 379
4th Gear Speed Limitation Function 379
Transmission Protection Function 381
Protection Function When Travel Direction is Changed 381
Shift Down Protection Function 381
Engine Overrun Prevention Function 382
Maximum Speed Limitation Function 382
Neutralizer Function 382
Directional Selector Switch Control Function 384
Transmission Cut-off Function 386
Component Parts of Power Train System 388
Drive Shaft 388
Torque Converter 390
Lockup Clutch ECMV 394
Transmission 397
Transmission Control Valve 414
Forward and Reverse Clutch ECMV and 1st, 2nd Clutch ECMV 417
3rd and 4th Clutch ECMV 422
Main Relief Valve and Torque Converter Relief Valve 428
Axle 430
Conventional Differential 432
Limited Slip Differential 435
Final Drive 440
Combination Switch 442
Shift Hold Switch 446
Kickdown Switch 447
Work Equipment System 448
Layout Drawing of Work Equipment System 448
Work Equipment System Diagram (Applicable Machine: 100001 to 101011) 450
Work Equipment System Diagram (Applicable Machine: 101012 and Up) 452
Work Equipment Control System 454
Work Equipment Speed Pattern Control Function by Work Equipment Lever Stroke 454
Work Equipment Lever Detent Position and Work Equipment Startup Current Control Function 454
Work Equipment Lever Operating Function System Diagram 455
Work Equipment Lever Operation Function 456
Bucket Priority Control Function 456
Boom Stop Modulation Function 456
Work Equipment Neutral Lock System 458
Work Equipment Neutral Lock System Diagram 458
Function of Work Equipment Neutral Lock System 458
Remote Positioner System 460
Remote Bucket Positioner System Diagram 460
Function of Remote Bucket Positioner System 460
Remote Boom Positioner System Diagram 461
Function of Remote Boom Positioner System 461
Bucket Positioner and Boom Positioner 465
Structure of Bucket Positioner and Boom Positioner 465
Auto-Digging System 466
Auto-Digging System Diagram 466
Function of Auto-Digging System 466
Semi-Auto Digging System 468
Semi-Auto Digging System Diagram 468
Function of Semi-Auto Digging System 468
ECSS 470
ECSS Diagram 470
Function of ECSS 470
Operation of ECSS 470
Component Parts of Work Equipment System 472
Work Equipment Lock Solenoid Valve 472
Pilot Circuit Accumulator 473
ECSS Circuit Accumulator 474
Work Equipment Electric Lever 476
Multifunction Mono-Lever 479
Steering System 480
Layout Drawing of Steering System 480
Secondary Steering System 481
Secondary Steering System Diagram 481
Function of Secondary Steering System 481
Joystick Steering System 483
Function of Joystick Steering System 483
Joystick Control Function 483
Joystick Neutral Safety Function 486
Joystick Neutral Interlock Function 486
Joystick Speed Sensing Steering Function 486
Joystick Hi/Lo Selector Function 487
Steering Column 488
Structure of Steering Column 488
Component Parts of Steering System 489
Orbitrol Valve 490
Stop Valve 494
Steering Valve 495
Secondary Steering Pump 508
Secondary Steering Motor 509
Joystick Knob 510
Brake System 511
Layout Drawing of Brake System 511
Layout Drawing of Brake Cooling System 513
Parking Brake Control System 517
System Diagram of Parking Brake Control System 517
Operation of Parking Brake Control System 517
Brake Cooling Control System 519
Brake Cooling Control System Diagram 519
Function of Brake Cooling Control System 522
Component Parts of Brake System 523
Charge Valve 523
Brake Circuit Accumulator 528
Parking Brake Solenoid Valve 530
Parking Brake Emergency Release Valve 532
Brake Valve 533
Slack Adjuster 537
Brake 539
Parking Brake 542
Flow Priority Valve 544
Brake Cooling Motor 546
Brake Cooling Pump 550
Brake Cooling Pump Motor 551
Brake Cooling Oil Cooler 552
Brake Cooling Fan 555
Manual Type Valve 556
Auto-Greasing System 557
Layout Drawing of Auto-Greasing System 557
Specifications of Auto-Greasing System 559
Function of Auto-Greasing System 561
Auto-Greasing System 562
Auto-Greasing Pump 562
Undercarriage and Frame 563
Frame, Axle Mount and Center Hinge Pin 563
Structure of Frame, Axle Mount and Center Hinge Pin 563
Function of Frame, Axle Mount and Center Hinge Pin 563
Tires 565
Features of Radial Tire When Compared with Bias Tire 565
Structure of Radial Tire 565
Function of Radial Tire 566
Structure of Bias Tire 566
Function of Bias Tire 566
Work Equipment 567
Structure of Work Equipment 567
Structure of Bucket 568
CAB Related Parts 569
ROPS CAB 569
Structure of ROPS CAB (Machine with KOMTRAX Terminal) 569
Structure of ROPS CAB (Machine with Gateway Function Controller) 570
Function of ROPS CAB 570
20 Standard Value Table 571
Table of Contents 572
Abbreviation List 573
Standard Value Table for Engine 579
Standard Value Table for Engine: WA470-8 579
Standard Value Table for Machine 583
Standard Value Table for Machine: WA470-8 583
Machine Posture and Procedures to Measure Performance 601
Standard Value Table for Electricity 604
Standard Value Table for Electricity 604
30 Testing and Adjusting 623
Table of Contents 624
Precautions Before Work 628
Abbreviation List 629
Related Information on Testing and Adjusting 635
Differences In Machine Monitor Symbols 635
Tools for Testing and Adjusting 636
Sketch of Tools for Testing and Adjusting 645
Engine and Cooling System 647
Examine Engine Speed 647
How to Examine Engine Speed 647
Examine Boost Pressure 653
How to Examine Boost Pressure 653
Examine Exhaust Gas Temperature 656
How to Examine Exhaust Gas Temperature 656
Examine Exhaust Gas Color 658
How to Examine Exhaust Gas Color with the Handy Smoke Checker 658
How to Examine Exhaust Gas Color with Smoke Meter 660
Examine Mass Air Flow and Temperature Sensor 661
How to Examine Mass Air Flow and Temperature Sensor 661
Examine and Adjust Valve Clearance 663
How to Examine Valve Clearance 663
How to Adjust Valve Clearance 665
Examine Compression Pressure 666
How to Examine Compression Pressure 666
Examine Blowby Pressure 670
How to Examine Blowby Pressure 670
Examine Engine Oil Pressure 673
How to Examine Engine Oil Pressure on Machine Monitor 673
How to Examine Engine Oil Pressure by Testing Tool 674
Examine EGR Valve and VGT Oil Pressure 675
How to Examine EGR Valve and VGT Oil Pressure 675
Examine Fuel Pressure 677
How to Examine Fuel Pressure 677
Examine Fuel Return Rate and Leakage 679
How to Examine Fuel Return Rate and Leakage 680
Bleed Air from Fuel System 683
How to Bleed Air from Fuel System 684
Examine Fuel Circuit for Leakage 685
How to Examine Fuel System for Leakage 685
Handle Cylinder Cut-out Mode Operation 687
Handle No-Injection Cranking Operation 688
Examine KDPF, SCR and Muffler Stack for Looseness and Damage 689
How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage 689
Examine Installed Condition of Cylinder Heads and Manifolds 690
How to Examine Installed Condition of Cylinder Heads and Manifolds 690
Examine Engine Piping for Damage and Looseness 691
How to Examine Engine Piping for Damage and Looseness 691
Examine and Adjust Air Conditioner Compressor Belt Tension 692
How to Examine Air Conditioner Compressor Belt Tension 692
How to Adjust Air Conditioner Compressor Belt Tension 692
Examine Alternator Belt 694
How to Examine Alternator Belt 694
Examine Automatic Tensioner 696
How to Examine Automatic Tensioner 696
Clean Fuel Doser 699
How to Clean Fuel Doser 699
Write Injector Compensation Value to Engine Controller 701
How to Write Injector Compensation Value 701
Write Correction for Ash in Soot Accumulation to Engine Controller 708
How to Write Correction for Ash in Soot Accumulation to Engine Controller 708
Examine SCR Related Functions 709
Examine DEF Pump Raised Pressure 713
Examine Injection Volume from DEF Injector 716
Examine DEF Line Heater Relay 1 721
Examine DEF Line Heater Relay 2 725
Examine DEF Pump Heater Relay 729
Examine DEF Tank Heater Valve 733
Examine SCR Denitration Efficiency 737
Clean DEF Tank 741
How to Clean DEF Tank 741
Clean DEF Pump 745
How to Clean DEF Pump 745
Power Train 751
Examine and Adjust Power Train Oil Pressure 751
How to Examine Power Train Oil Pressure 753
How to Adjust Power Train Oil Pressure 770
Adjust Transmission Input Shaft Speed Sensor 772
How to Adjust Transmission Input Shaft Speed Sensor 772
Adjust Transmission Output Shaft Speed Sensor 774
How to Adjust Transmission Output Shaft Speed Sensor 774
Flush Torque Converter and Transmission Hydraulic Circuit 775
How to Flush Torque Converter and Transmission Hydraulic Circuit 775
Move Disabled Machine Due to Transmission Valve Failure 778
How to Move Disabled Machine Due to Transmission Valve Failure 779
Examine Drive Shaft for Looseness, Backlash, and Damage 782
How to Examine Drive Shaft for Looseness, Backlash, and Damage 782
Steering System 783
Examine Steering Wheel 783
How to Examine Steering Wheel 783
Examine and Adjust Steering Circuit Oil Pressure 785
How to Examine Steering Circuit Oil Pressure 785
How to Adjust Steering Circuit Oil Pressure 788
Bleed Air from Steering Cylinder Circuit 789
How to Bleed Air from Steering Cylinder Circuit 789
Examine and Adjust Steering Stop Valve 791
How to Examine Steering Stop Valve 791
How to Adjust Steering Stop Valve 791
Brake System 792
Release Remained Pressure in Brake Accumulator Circuit 792
How to Release Remained Pressure in Brake Accumulator Circuit 792
Examine Wheel Brake Oil Pressure 793
How to Examine Wheel Brake Oil Pressure 793
Examine and Adjust Accumulator Charge Pressure 796
How to Examine Accumulator Charge Pressure 796
How to Adjust Accumulator Charge Pressure 797
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas 798
How to Examine Accumulator Nitrogen Gas Pressure for Brake 798
How to Charge Accumulator Nitrogen Gas for Brake 801
How to Release Nitrogen Gas When You Discard Accumulator 805
Bleed Air from Brake Circuit 807
How to Bleed Air from Brake Circuit 807
Examine Brake Performance 810
How to Examine Brake Performance 810
Examine Brake Pedal 811
How to Examine Brake Pedal 811
Examine and Adjust Brake Pedal and Linkage 812
How to Examine Brake Pedal and Linkage 812
How to Adjust Brake Pedal and Linkage 812
Examine Pressure Decrease of Wheel Brake 813
How to Examine Pressure Decrease of Wheel Brake 814
Examine Wear of Wheel Brake Disc 816
How to Examine Wear of Wheel Brake Disc 816
Examine Parking Brake Oil Pressure 818
How to Examine Parking Brake Oil Pressure 818
Examine Parking Brake Performance 820
How to Examine Parking Brake Performance 820
Release Parking Brake Manually 821
How to Release Parking Brake Manually 821
Examine Wear Volume of Parking Brake Disc 823
How to Examine Wear Quantity of Parking Brake Disc 823
Hydraulic System 825
Release Remained Pressure from Work Equipment Circuit 825
How to Release Remained Pressure from Work Equipment Circuit 825
Examine and Adjust Work Equipment Oil Pressure 827
How to Examine Work Equipment Oil Pressure 827
How to Adjust Work Equipment Oil Pressure 832
Examine and Adjust Work Equipment EPC Oil Pressure 834
How to Examine Work Equipment EPC Oil Pressure 834
How to Adjust Work Equipment EPC Oil Pressure 837
Bleed Air from Work Equipment Circuit 839
How to Bleed Air from Work Equipment Circuit 839
Examine Cooling Fan Speed 840
How to Examine Cooling Fan Speed 840
Examine Cooling Fan Circuit Oil Pressure 842
How to Examine Cooling Fan Circuit Oil Pressure 842
Bleed Air from Cooling Fan Circuit 845
How to Bleed Air from Cooling Fan Circuit 845
Examine ECSS Accumulator Nitrogen Gas Pressure and Charge Accumulator with Nitrogen Gas 847
How to Examine ECSS Accumulator Nitrogen Gas Pressure 847
How to Charge ECSS Accumulator with Nitrogen Gas 849
Work Equipment 853
Examine and Adjust Bucket Potentiometer Lever 853
How to Examine Bucket Positioner Detection Lever 853
How to Adjust Bucket Positioner Detection Lever 853
Examine and Adjust Boom Potentiometer Lever 855
How to Examine Boom Position Detection Lever 855
How to Adjust Boom Position Detection Lever 855
CAB Related Parts 856
Examine Directional Lever 856
How to Examine Directional Lever 856
Examine Work Equipment Control Lever 857
How to Examine Work Equipment Control Lever 857
Adjust Play of Operator Seat 860
How to Adjust Play of Operator Seat 860
Electrical System 861
Set and Adjust Each Equipment 861
Prepare for Transmission ECMV Current Adjustment 863
How to Adjust Transmission ECMV Current 865
How to Set and Reset Transmission Initial Learning 868
Set and Operate Machine Monitor 873
Operator Mode 877
Function to Show Technician Identification Status Screen 877
Function to Show Operator Identification Input Screen 877
Examine Function by LCD (Liquid Crystal Display) 878
Examine Function of Service Meter and Odometer 879
How to Set Usage Limitation and Change Maintenance Password 879
Service Mode 883
How to Operate Service Mode 883
How to See Pre-defined Monitoring Information 886
How to Examine Self-Define Monitor Information 893
Abnormality Record Menu 909
How to See Maintenance Record 914
Maintenance Mode Setting 916
How to Set Phone Number Entry 921
Default Menu 923
Diagnostic Tests Menu 938
Adjustment Menu 949
No-Injection Cranking Operation 982
KOMTRAX Settings Menu 985
How to Show Service Message 990
How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 992
How to Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 996
How to Start Up KOMTRAX System (Machine with Gateway Function Controller) 998
How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller)1004
Adjust Rearview Camera Angle1006
How to Adjust Rearview Camera Angle1006
Set Region of Bluetooth(R) Compatible Radio1008
How to Set Region of Bluetooth(R) Compatible Radio1008
Handle Voltage Circuit of Engine Controller1010
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal)1011
Handle Battery Disconnect Switch (Machine with Gateway Function Controller)1012
Examine Diodes1013
How to Examine Diodes by Digital Tester1013
How to Examine Diodes by Analog Tester1013
Auto-Greasing Device1014
Bleed the Air in Auto-Greasing System1014
How to Bleed the Air in Auto-Greasing System1014
Correspondence in Case of Grease Leakage from over Pressure Protection Valve1017
Correspondence in Case of Grease Leakage from over Pressure Protection Valve1017
Change Lubrication Time and Lubrication Interval1018
How to Change Lubrication Time and Lubrication Interval1019
Examine and Fill Auto-Greasing1021
How to Examine Auto-Greasing1021
How to Fill Auto-Greasing1022
Pm Clinic1023
Pm Clinic Service1023
Pm Clinic Check Sheet1026
40 Troubleshooting1037
Table of Contents1038
Precautions Before Work1052
Abbreviation List1053
Related Information to Troubleshooting1059
General Troubleshooting Points1059
Troubleshooting Points for Urea SCR System1060
Sequence of Events in Troubleshooting1074
Checks Before Troubleshooting1076
Inspection Procedure Before Troubleshooting1078
Walk-Around Check1078
Test in Accordance with Testing Procedure1080
Examine Fuel Level and Type1080
Examine for Impure Ingredient in Fuel1080
Examine DEF Level and Type1081
Examine Fuel Prefilter1081
Examine Fuel Main Filter1083
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type1084
Examine Coolant Level (Reservoir Tank)1084
Examine Air Cleaner Clogging1085
Clean Outer Element1086
Replace Element1088
Examine Hydraulic Oil Level1089
Examine Hydraulic Oil Strainer1090
Examine Hydraulic Oil Filter1091
Examine Oil Level in Transmission Case1092
Examine Oil Level in Front Axle Case1094
Examine Oil Level in Rear Axle Case1095
Bleed Air from Fuel System1095
Bleed Air from Hydraulic System1095
How to Examine Electric Equipment1095
Preparation for Troubleshooting of Electrical System1102
Procedure for Troubleshooting1115
Symptom and Troubleshooting Numbers1117
Information Shown in Troubleshooting Table1122
Connector List and Layout (Machine with KOMTRAX Terminal)1124
Connector List and Layout (Machine with Gateway Function Controller)1144
Connector Contact Connection Table1164
T-Branch Box and T-Branch Adapter Table1204
Fuse Location Table (Machine with KOMTRAX Terminal)1210
Fuse Location Table (Machine with Gateway Function Controller)1214
Precautions When You Clean and Replace KDPF (KCSF and KDOC)1218
Prepare Troubleshoot Machine Monitor1222
Procedure to Make Harness Checker on Machine Monitor LCD Unit1224
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])1230
Failure Code Table1232
Troubleshooting by Failure Code (Display of Code)1257
Failure Code [1500L0]1257
Failure Code [15SAL1]1259
Failure Code [15SALH]1261
Failure Code [15SBL1]1264
Failure Code [15SBLH]1266
Failure Code [15SEL1]1269
Failure Code [15SELH]1271
Failure Code [15SFL1]1274
Failure Code [15SFLH]1276
Failure Code [15SGL1]1279
Failure Code [15SGLH]1281
Failure Code [15SHL1]1284
Failure Code [15SHLH]1287
Failure Code [2F00MA]1291
Failure Code [2F00MB]1298
Failure Code [2G42ZG]1303
Failure Code [2G43ZG]1306
Failure Code [879AKA]1309
Failure Code [879AKB]1312
Failure Code [879BKA]1315
Failure Code [879BKB]1318
Failure Code [879CKA]1321
Failure Code [879CKB]1324
Failure Code [879DKZ]1327
Failure Code [879EMC]1330
Failure Code [879FMC]1335
Failure Code [989A00]1340
Failure Code [989L00]1342
Failure Code [989M00]1343
Failure Code [989N00]1344
Failure Code [A1U0N3]1345
Failure Code [A1U0N4]1348
Failure Code [AA10NX]1351
Failure Code [AB00KE]1354
Failure Code [AB00KY]1356
Failure Code [AQ10N3]1358
Failure Code [AS00N3]1360
Failure Code [AS00R2]1362
Failure Code [AS00R3]1363
Failure Code [AS00R4]1364
Failure Code [AS00R5]1365
Failure Code [AS00R6]1366
Failure Code [AS00ZK]1367
Failure Code [AS10KM]1369
Failure Code [AS10NR]1370
Failure Code [AS10NT]1372
Failure Code [B@BAZG]1373
Failure Code [B@BAZK]1374
Failure Code [B@BCNS]1377
Failure Code [B@BCQA]1378
Failure Code [B@BCZK]1381
Failure Code [B@C7NS]1384
Failure Code [B@CENS]1386
Failure Code [B@HANS]1388
Failure Code [CA115]1390
Failure Code [CA122]1391
Failure Code [CA123]1395
Failure Code [CA131]1399
Failure Code [CA132]1402
Failure Code [CA135]1406
Failure Code [CA141]1410
Failure Code [CA144]1414
Failure Code [CA145]1418
Failure Code [CA153]1421
Failure Code [CA154]1424
Failure Code [CA187]1428
Failure Code [CA221]1431
Failure Code [CA222]1435
Failure Code [CA227]1439
Failure Code [CA234]1440
Failure Code [CA238]1442
Failure Code [CA239]1444
Failure Code [CA249]1446
Failure Code [CA256]1450
Failure Code [CA271]1454
Failure Code [CA272]1457
Failure Code [CA273]1459
Failure Code [CA274]1462
Failure Code [CA322]1464
Failure Code [CA323]1468
Failure Code [CA324]1472
Failure Code [CA325]1476
Failure Code [CA331]1480
Failure Code [CA332]1484
Failure Code [CA343]1488
Failure Code [CA351]1489
Failure Code [CA352]1490
Failure Code [CA356]1493
Failure Code [CA357]1496
Failure Code [CA386]1500
Failure Code [CA431]1501
Failure Code [CA432]1505
Failure Code [CA441]1509
Failure Code [CA442]1512
Failure Code [CA449]1513
Failure Code [CA451]1514
Failure Code [CA452]1517
Failure Code [CA515]1520
Failure Code [CA516]1523
Failure Code [CA553]1526
Failure Code [CA555]1529
Failure Code [CA556]1531
Failure Code [CA559]1533
Failure Code [CA595]1540
Failure Code [CA687]1541
Failure Code [CA689]1545
Failure Code [CA691]1550
Failure Code [CA692]1553
Failure Code [CA697]1557
Failure Code [CA698]1558
Failure Code [CA731]1559
Failure Code [CA778]1561
Failure Code [CA1117]1566
Failure Code [CA1664]1568
Failure Code [CA1669]1572
Failure Code [CA1673]1574
Failure Code [CA1677]1576
Failure Code [CA1678]1578
Failure Code [CA1682]1580
Failure Code [CA1683]1589
Failure Code [CA1684]1592
Failure Code [CA1686]1595
Failure Code [CA1691]1597
Failure Code [CA1694]1601
Failure Code [CA1695]1606
Failure Code [CA1696]1607
Failure Code [CA1712]1610
Failure Code [CA1713]1614
Failure Code [CA1714]1617
Failure Code [CA1715]1619
Failure Code [CA1776]1621
Failure Code [CA1777]1625
Failure Code [CA1843]1630
Failure Code [CA1844]1633
Failure Code [CA1879]1637
Failure Code [CA1881]1641
Failure Code [CA1883]1645
Failure Code [CA1885]1650
Failure Code [CA1887]1653
Failure Code [CA1921]1656
Failure Code [CA1922]1659
Failure Code [CA1923]1666
Failure Code [CA1924]1669
Failure Code [CA1925]1673
Failure Code [CA1927]1676
Failure Code [CA1928]1679
Failure Code [CA1942]1682
Failure Code [CA1963]1684
Failure Code [CA1977]1691
Failure Code [CA1993]1695
Failure Code [CA2185]1699
Failure Code [CA2186]1702
Failure Code [CA2249]1705
Failure Code [CA2265]1706
Failure Code [CA2266]1709
Failure Code [CA2271]1712
Failure Code [CA2272]1715
Failure Code [CA2349]1719
Failure Code [CA2353]1723
Failure Code [CA2357]1726
Failure Code [CA2381]1729
Failure Code [CA2382]1732
Failure Code [CA2383]1736
Failure Code [CA2386]1740
Failure Code [CA2387]1743
Troubleshooting Flowchart1747
Failure Code [CA2555]1748
Failure Code [CA2556]1752
Failure Code [CA2637]1755
Failure Code [CA2639]1759
Failure Code [CA2732]1763
Failure Code [CA2733]1766
Failure Code [CA2741]1769
Failure Code [CA2765]1771
Failure Code [CA2771]1772
Failure Code [CA2777]1781
Failure Code [CA2878]1784
Failure Code [CA2881]1789
Failure Code [CA2976]1795
Failure Code [CA3133]1799
Failure Code [CA3134]1802
Failure Code [CA3135]1805
Failure Code [CA3142]1810
Failure Code [CA3143]1811
Failure Code [CA3144]1812
Failure Code [CA3146]1816
Failure Code [CA3147]1817
Failure Code [CA3148]1818
Failure Code [CA3151]1822
Failure Code [CA3165]1831
Failure Code [CA3167]1835
Failure Code [CA3229]1840
Failure Code [CA3231]1844
Failure Code [CA3232]1848
Failure Code [CA3235]1854
Failure Code [CA3239]1858
Failure Code [CA3241]1862
Failure Code [CA3242]1867
Failure Code [CA3251]1871
Failure Code [CA3253]1875
Failure Code [CA3254]1880
Failure Code [CA3255]1885
Failure Code [CA3256]1890
Failure Code [CA3311]1894
Failure Code [CA3312]1899
Failure Code [CA3313]1905
Failure Code [CA3314]1907
Failure Code [CA3315]1908
Failure Code [CA3316]1913
Failure Code [CA3317]1915
Failure Code [CA3318]1916
Failure Code [CA3319]1921
Failure Code [CA3321]1922
Failure Code [CA3322]1924
Failure Code [CA3419]1929
Failure Code [CA3421]1931
Failure Code [CA3497]1934
Failure Code [CA3498]1936
Failure Code [CA3543]1938
Failure Code [CA3545]1947
Failure Code [CA3547]1950
Failure Code [CA3558]1952
Failure Code [CA3559]1955
Failure Code [CA3562]1958
Failure Code [CA3563]1961
Failure Code [CA3567]1965
Failure Code [CA3568]1969
Failure Code [CA3571]1978
Failure Code [CA3572]1982
Failure Code [CA3574]1986
Failure Code [CA3575]1991
Failure Code [CA3577]1994
Failure Code [CA3578]1997
Failure Code [CA3582]2000
Failure Code [CA3583]2012
Failure Code [CA3596]2015
Failure Code [CA3649]2021
Failure Code [CA3681]2024
Failure Code [CA3682]2031
Failure Code [CA3713]2038
Failure Code [CA3717]2042
Failure Code [CA3718]2044
Failure Code [CA3725]2046
Failure Code [CA3748]2051
Failure Code [CA3751]2055
Failure Code [CA3755]2057
Failure Code [CA3866]2060
Failure Code [CA3867]2065
Failure Code [CA3868]2069
Failure Code [CA3899]2075
Failure Code [CA3911]2078
Failure Code [CA3912]2084
Failure Code [CA3932]2087
Failure Code [CA3933]2090
Failure Code [CA3934]2093
Failure Code [CA3935]2097
Failure Code [CA3936]2100
Failure Code [CA4151]2102
Failure Code [CA4152]2108
Failure Code [CA4155]2114
Failure Code [CA4156]2117
Failure Code [CA4157]2121
Failure Code [CA4158]2124
Failure Code [CA4159]2126
Failure Code [CA4161]2128
Failure Code [CA4162]2131
Failure Code [CA4163]2134
Failure Code [CA4164]2137
Failure Code [CA4165]2140
Failure Code [CA4166]2143
Failure Code [CA4168]2145
Failure Code [CA4169]2149
Failure Code [CA4171]2152
Failure Code [CA4249]2156
Failure Code [CA4251]2159
Failure Code [CA4259]2162
Failure Code [CA4261]2166
Failure Code [CA4277]2170
Failure Code [CA4281]2175
Failure Code [CA4459]2180
Failure Code [CA4461]2184
Failure Code [CA4658]2188
Failure Code [CA4731]2193
Failure Code [CA4732]2195
Failure Code [CA4739]2197
Failure Code [CA4768]2199
Failure Code [CA4769]2201
Failure Code [CA4842]2204
Failure Code [CA4952] (Machine with KOMTRAX Terminal)2209
Failure Code [CA4952] (Machine with Gateway Function Controller)2212
Failure Code [CA5115]2215
Failure Code [CA5179]2220
Failure Code [CA5181]2223
Failure Code [CA5383]2227
Failure Code [D150KA]2229
Failure Code [D150KB]2232
Failure Code [D150KY]2235
Failure Code [D160KA]2238
Failure Code [D160KB]2241
Failure Code [D160KY]2244
Failure Code [D191KA]2247
Failure Code [D191KB]2250
Failure Code [D191KY]2253
Failure Code [D192KA]2255
Failure Code [D192KB]2258
Failure Code [D192KY]2260
Failure Code [D193KA]2262
Failure Code [D193KB]2265
Failure Code [D193KY]2267
Failure Code [D193MC] (Applicable Machine: 100001 to 101011)2269
Failure Code [D193MC] (Applicable Machine: 101012 and Up)2272
Failure Code [D19JKZ]2275
Failure Code [D1E6KA]2278
Failure Code [D1E6KB]2281
Failure Code [D1E6KY]2284
Failure Code [D5ZHKA]2287
Failure Code [D5ZHKB]2290
Failure Code [D5ZHKZ]2293
Failure Code [D5ZHL6]2296
Failure Code [D811MC] (Machine with KOMTRAX Terminal)2298
Failure Code [D811MC] (Machine with Gateway Function Controller)2299
Failure Code [D862KA] (Machine with KOMTRAX Terminal)2300
Failure Code [D862KA] (Machine with Gateway Function Controller)2301
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal)2302
Failure Code [D8ALKA] (Machine with Gateway Function Controller)2305
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal)2308
Failure Code [D8ALKB] (Machine with Gateway Function Controller)2310
Failure Code [D8AQK4] (Machine with KOMTRAX Terminal)2312
Failure Code [D8AQK4] (Machine with Gateway Function Controller)2313
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal)2314
Failure Code [D8AQKR] (Machine with Gateway Function Controller)2317
Failure Code [D8G1KT]2320
Failure Code [D8G6KT]2321
Failure Code [DAF0KT]2322
Failure Code [DAF0MB]2323
Failure Code [DAF0MC]2324
Failure Code [DAF3KK]2325
Failure Code [DAF8KB]2329
Failure Code [DAFDKB]2331
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal)2333
Failure Code [DAFGMC] (Machine with Gateway Function Controller)2334
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal)2335
Failure Code [DAFLKA] (Machine with Gateway Function Controller)2337
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal)2339
Failure Code [DAFLKB] (Machine with Gateway Function Controller)2342
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal)2345
Failure Code [DAFQKR] (Machine with Gateway Function Controller)2346
Failure Code [DAQ0KK]2347
Failure Code [DAQ0KT]2351
Failure Code [DAQ0MC]2352
Failure Code [DAQ1KA]2353
Failure Code [DAQ2KK]2356
Failure Code [DAQ2KT]2360
Failure Code [DAQ4KB]2363
Failure Code [DAQ9KQ]2366
Failure Code [DAQLKA] (Machine with KOMTRAX Terminal)2368
Failure Code [DAQLKA] (Machine with Gateway Function Controller)2371
Failure Code [DAQLKB] (Machine with KOMTRAX Terminal)2374
Failure Code [DAQLKB] (Machine with Gateway Function Controller)2377
Failure Code [DAQQKR]2380
Failure Code [DAQRKR]2382
Failure Code [DAQRMA]2384
Failure Code [DAZ9KQ]2386
Failure Code [DAZQKR]2387
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal)2389
Failure Code [DB2QKR] (Machine with Gateway Function Controller)2399
Failure Code [DB2RKR]2408
Failure Code [DB90KK] (Machine with KOMTRAX Terminal)2416
Failure Code [DB90KK](Machine with Gateway Function Controller)2420
Failure Code [DB90KT]2424
Failure Code [DB90MC]2425
Failure Code [DB91KA]2426
Failure Code [DB92KK] (Machine with KOMTRAX Terminal)2429
Failure Code [DB92KK] (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011)2433
Failure Code [DB92KK] (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up)2437
Failure Code [DB92KT]2441
Failure Code [DB95KX] (Applicable Machine: 100001 to 101011)2444
Failure Code [DB95KX] (Applicable Machine: 101012 and Up)2448
Failure Code [DB96KX] (Applicable Machine: 100001 to 101011)2453
Failure Code [DB96KX] (Applicable Machine: 101012 and Up)2456
Failure Code [DB99KQ]2459
Failure Code [DB9LKA] (Machine with KOMTRAX Terminal)2461
Failure Code [DB9LKA] (Machine with Gateway Function Controller)2463
Failure Code [DB9LKB] (Machine with KOMTRAX Terminal)2465
Failure Code [DB9LKB] (Machine with Gateway Function Controller)2467
Failure Code [DB9QKR]2469
Failure Code [DB9RKR]2471
Failure Code [DB9RMA]2473
Failure Code [DBE5KX] (Applicable Machine: 100001 to 101011)2475
Failure Code [DBE5KX] (Applicable Machine: 101012 and Up)2478
Failure Code [DBE6KX]2481
Failure Code [DD1ALD]2483
Failure Code [DDAAL6]2486
Failure Code [DDB6L4]2489
Failure Code [DDD1LD]2492
Failure Code [DDK3KA]2495
Failure Code [DDK3KB]2499
Failure Code [DDK6KA]2503
Failure Code [DDK6KB]2507
Failure Code [DDKLKA] (Applicable Machine: 100001 to 101011)2510
Failure Code [DDKLKA] (Applicable Machine: 101012 and Up)2513
Failure Code [DDKLKB] (Applicable Machine: 100001 to 101011)2516
Failure Code [DDKLKB] (Applicable Machine: 101012 and Up)2519
Failure Code [DDNRKA]2521
Failure Code [DDNRKY] (Applicable Machine: 100001 to 101011)2524
Failure Code [DDNRKY] (Applicable Machine: 101012 and Up)2527
Failure Code [DDT0L4]2530
Failure Code [DDT4LD]2533
Failure Code [DDT9LD]2535
Failure Code [DDTALD]2537
Failure Code [DDW9LD]2540
Failure Code [DDWLLD]2542
Failure Code [DF10KA]2544
Failure Code [DF10KA]2548
Failure Code [DGF1KA]2552
Failure Code [DGF1KB]2556
Failure Code [DGH2KX]2558
Failure Code [DGR2KB]2561
Failure Code [DGR2KZ]2563
Failure Code [DGT1KA]2566
Failure Code [DGT1KB]2570
Failure Code [DH21KA]2573
Failure Code [DH21KB]2577
Failure Code [DHA4KA]2580
Failure Code [DHAAMA]2583
Failure Code [DHACMA]2586
Failure Code [DHPCKX]2589
Failure Code [DHPDKX]2593
Failure Code [DHT1KX]2597
Failure Code [DHT5KX]2600
Failure Code [DHT7KX]2604
Failure Code [DHT8KA]2608
Failure Code [DHT8KB]2612
Failure Code [DHT8ZG]2615
Failure Code [DHUDKA]2616
Failure Code [DHUDKB]2620
Failure Code [DJF1KA]2623
Failure Code [DK55KA]2626
Failure Code [DK55KY]2630
Failure Code [DK55L5]2633
Failure Code [DK59KA] (Applicable Machine: 100001 to 101011)2634
Failure Code [DK59KA] (Applicable Machine: 101012 and Up)2638
Failure Code [DK59KY] (Applicable Machine: 100001 to 101011)2642
Failure Code [DK59KY] (Applicable Machine: 101012 and Up)2646
Failure Code [DK59L8] (Applicable Machine: 100001 to 101011)2650
Failure Code [DK59L8] (Applicable Machine: 101012 and Up)2656
Failure Code [DK5AKA] (Applicable Machine: 100001 to 101011)2662
Failure Code [DK5AKA] (Applicable Machine: 101012 and Up)2666
Failure Code [DK5AKY] (Applicable Machine: 100001 to 101011)2670
Failure Code [DK5AKY] (Applicable Machine: 101012 and Up)2674
Failure Code [DK5BKA] (Applicable Machine: 100001 to 101011)2678
Failure Code [DK5BKA] (Applicable Machine: 101012 and Up)2682
Failure Code [DK5BKY] (Applicable Machine: 100001 to 101011)2686
Failure Code [DK5BKY] (Applicable Machine: 101012 and Up)2690
Failure Code [DK5BL8] (Applicable Machine: 100001 to 101011)2694
Failure Code [DK5BL8] (Applicable Machine: 101012 and Up)2699
Failure Code [DK5CKA] (Applicable Machine: 100001 to 101011)2705
Failure Code [DK5CKA] (Applicable Machine: 101012 and Up)2709
Failure Code [DK5CKY] (Applicable Machine: 100001 to 101011)2713
Failure Code [DK5CKY] (Applicable Machine: 101012 and Up)2717
Failure Code [DK5DKA] (Applicable Machine: 100001 to 101011)2721
Failure Code [DK5DKA] (Applicable Machine: 101012 and Up)2725
Failure Code [DK5DKY] (Applicable Machine: 100001 to 101011)2729
Failure Code [DK5DKY] (Applicable Machine: 101012 and Up)2733
Failure Code [DK5DL8] (Applicable Machine: 100001 to 101011)2737
Failure Code [DK5DL8] (Applicable Machine: 101012 and Up)2743
Failure Code [DK5EKA] (Applicable Machine: 100001 to 101011)2749
Failure Code [DK5EKA] (Applicable Machine: 101012 and Up)2753
Failure Code [DK5EKY] (Applicable Machine: 100001 to 101011)2757
Failure Code [DK5EKY] (Applicable Machine: 101012 and Up)2761
Failure Code [DK5FKA]2765
Failure Code [DK5FKY]2769
Failure Code [DK5FL8]2773
Failure Code [DK5GKA]2777
Failure Code [DK5GKY]2781
Failure Code [DKA0KA]2785
Failure Code [DKA0KY]2789
Failure Code [DKA0L0]2792
Failure Code [DKA1KA]2795
Failure Code [DKA1KY]2798
Failure Code [DLF1KA]2801
Failure Code [DLF1LC]2804
Failure Code [DLM3KA]2807
Failure Code [DLM3LC]2810
Failure Code [DLT3KA]2813
Failure Code [DLT3LC]2816
Failure Code [DPQ1KR]2819
Failure Code [DPQ2KR]2824
Failure Code [DPQ3KR]2829
Failure Code [DSJ0KR]2834
Failure Code [DT20KB] (Applicable Machine: 100001 to 101011)2838
Failure Code [DT20KB] (Applicable Machine: 101012 and Up)2841
Failure Code [DT22KB]2843
Failure Code [DT23KB]2846
Failure Code [DV00KB]2849
Failure Code [DW4PKA]2851
Failure Code [DW4PKB]2855
Failure Code [DW4PKY]2858
Failure Code [DW4QKA]2861
Failure Code [DW4QKB]2865
Failure Code [DW4QKY]2868
Failure Code [DW4RKA]2871
Failure Code [DW4RKB]2874
Failure Code [DW4RKY]2877
Failure Code [DW4SKA]2880
Failure Code [DW4SKB]2883
Failure Code [DW4SKY]2886
Failure Code [DW7BKA]2889
Failure Code [DW7BKB]2892
Failure Code [DW7BKY]2895
Failure Code [DWM1KA] (Applicable Machine: 100001 to 101011)2897
Failure Code [DWM1KA] (Applicable Machine: 101012 and Up)2900
Failure Code [DWM1KB] (Applicable Machine: 100001 to 101011)2904
Failure Code [DWM1KB] (Applicable Machine: 101012 and Up)2907
Failure Code [DWM1KY]2910
Failure Code [DWN6KA]2913
Failure Code [DWN6KB]2916
Failure Code [DWN6KY]2919
Failure Code [DWN8KA]2922
Failure Code [DWN8KB]2925
Failure Code [DWN8KY]2928
Failure Code [DX16KA]2931
Failure Code [DX16KB]2934
Failure Code [DX16KY]2937
Failure Code [DXA1KA]2939
Failure Code [DXA1KB]2942
Failure Code [DXA1KY]2945
Failure Code [DXANKA]2947
Failure Code [DXANKB]2951
Failure Code [DXANKY]2954
Failure Code [DXH1KA]2956
Failure Code [DXH1KB]2959
Failure Code [DXH1KY]2962
Failure Code [DXH4KA]2965
Failure Code [DXH4KB]2968
Failure Code [DXH4KY]2971
Failure Code [DXH5KA]2974
Failure Code [DXH5KB]2977
Failure Code [DXH5KY]2980
Failure Code [DXH6KA]2983
Failure Code [DXH6KB]2986
Failure Code [DXH6KY]2989
Failure Code [DXH7KA]2992
Failure Code [DXH7KB]2995
Failure Code [DXH7KY]2998
Failure Code [DXH8KA]3001
Failure Code [DXH8KB]3004
Failure Code [DXH8KY]3007
Failure Code [DXHHKA]3010
Failure Code [DXHHKB]3013
Failure Code [DXHHKY]3016
Failure Code [DXHJKA]3019
Failure Code [DXHJKB]3023
Failure Code [DXHJKY]3026
Failure Code [DXHKKA]3029
Failure Code [DXHKKB]3033
Failure Code [DXHKKY]3036
Failure Code [DXHLKA]3039
Failure Code [DXHLKB]3042
Failure Code [DXHLKY]3045
Failure Code [DXHMKA]3048
Failure Code [DXHMKB]3051
Failure Code [DXHMKY]3054
Failure Code [DY30MA]3057
Failure Code [DY30MC]3063
Failure Code [DY30ME]3071
Failure Code [F313KA]3073
Failure Code [F313KB]3075
Failure Code [F314KA]3077
Failure Code [F314KB]3079
Failure Code [F315KB]3081
Failure Code [F315KY]3083
Failure Code [F316KB]3085
Failure Code [F316KY]3087
Failure Code [F318KB]3089
Failure Code [F318KY]3091
Failure Code [F31AKB]3093
Failure Code [F31AKY]3095
Failure Code [F31BKB]3097
Failure Code [F31BKY]3099
Failure Code [F31CKB]3101
Failure Code [F31CKY]3103
Failure Code [F31DKB]3105
Failure Code [F31DKY]3107
Failure Code [F31EKB]3109
Failure Code [F31EKY]3111
Failure Code [FS10ZE]3113
Failure Code [LA00L3]3114
Troubleshooting of Electrical System (E-Mode)3115
Engine Does Not Start (Engine Does Not Crank)3115
Manual Preheating System Does Not Operate3122
Automatic Preheating System Does Not Operate3125
While Preheating is in Operation, Preheating Monitor Does Not Come On3128
The LCD Unit, LED Unit, and Meter Unit of the Machine Monitor Show Nothing3130
LCD Unit on Machine Monitor Shows Nothing3133
Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers)3136
LCD Screen on Machine Monitor Does Not Show Correctly3139
Meter Unit Display on Machine Monitor is Abnormal3142
Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal3145
LED Unit Lamp on Machine Monitor is Abnormal3148
Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly3150
Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate3153
Switch Panel Buzzer of Machine Monitor is Abnormal3156
Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally3159
DEF Level is Not Shown Correctly3160
Rearview Monitor Does Not Come On or Backlight Flickers3163
Rearview Monitor Images are Not Shown Clearly3166
Rearview Monitor Brightness Cannot be Adjusted3169
Night Mode Lamp of Rearview Monitor is Abnormal3173
Air Cleaner Clogging Indicator Lamp Does Not Come On3175
Radiator Coolant Level Caution Lamp Does Not Come On3177
Parking Brake Indicator Lamp Does Not Light When Parking Brake is Set to ON (Parking) Position3179
Brake Oil Pressure Caution Lamp Does Not Come On When Front Brake Accumulator Oil Pressure is Low3183
Brake Oil Pressure Caution Lamp Does Not Come On When Rear Brake Accumulator Oil Pressure is Low3184
Fuel Gauge Does Not Show Normally3185
Torque Converter Oil Temperature Gauge Does Not Increase, or Torque Converter Oil Temperature Caution Lamp Does Not Come On3187
Hydraulic Oil Temperature Gauge Does Not Rise or Hydraulic Oil Temperature Caution Lamp Does Not Come On3188
Seatbelt Caution Lamp Does Not Show Normally3190
Alarm Buzzer Does Not Operate3191
Alarm Buzzer Does Not Stop3193
Kickdown Does Not Operate When Kickdown Switch is ON Position3194
Hold Does Not Operate When Hold Switch is on Position3196
Parking Brake Does Not Operate Even If It is Applied, or the Brake Drags in Forward or Reverse Travel When Parking Brake is Released3198
Transmission Cut-off Mode is Not Selected or Not Released3202
Transmission Cut-off Setting Cannot be Released3204
Directional Selector (FNR) Switch Mode is Not Selected or Not Released3206
Engine Mode Selector Function Does Not Operate Normally When Engine Power Mode Selector Switch is Operated3208
Flow of Loader Pump Does Not Increase from the Minimum Rate3210
ECSS Function Cannot be Selected or Cannot be Released3211
Horn Does Not Sound3213
Horn Does Not Operate (Joystick Steering Specification)3216
Horn Does Not Stop3219
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On3222
Clearance Lamp and Tail Lamp Do Not Come On or Go Out3224
High and Low Beams of Headlamp Do Not Come On or Go Out3228
Low Beam of Headlamp Does Not Come On or Go Out3232
High Beam of Headlamp Does Not Come On or Go Out3234
Front Working Lamp Does Not Come On or Go Out3236
Front Working Lamp Does Not Come On or Go Out (EU Specifications)3241
Rear Working Lamp Does Not Come On or Go Out3246
Rear Working Lamp Does Not Come On or Go Out (For European Union)3250
Turn Signal Lamp and Hazard Lamp Do Not Come On or Go Out3255
Turn Signal Lamp Does Not Come On or Go Out3258
Hazard Lamp Does Not Come On or Go Out3261
Brake Lamp Does Not Come On or Stays Lit3265
Backup Lamp Does Not Come On or Stays Lit3269
Backup Buzzer Does Not Sound or Continues to Sound3272
Front Wiper Does Not Operate3274
Rear Wiper Does Not Operate3278
Fuel Feed Pump Does Not Operate or Stop Automatically3281
Fan Does Not Rotate in Reverse3284
Fan Remains Rotated in Reverse3285
Window Washer Does Not Operate3286
KOMTRAX System Does Not Operate Correctly3289
Auto-Greasing Pump Display Shows [FCS]3290
Auto-Greasing Pump Display Shows [FLL]3292
Auto-Greasing System Does Not Operate or Stop3293
When Work Equipment Lock Switch is Operated, Work Equipment is Not Locked or Unlocked3295
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)3297
Information Shown in Troubleshooting Table (H-Mode)3297
Failure Mode and Cause Table3298
Machine Does Not Start3314
Lockup is Not Released3318
Torque Converter Lockup Clutch Does Not Engage3319
Travel Speed is Slow, Bucket Thrust Force is Weak, Gradability is Low, or Gear Speed Does Not Shift3320
Strong Shocks are Made When You Start Machine or Shift Gears3324
Time Lag is Large When You Start Machine or Shift Gears3327
Torque Converter Oil Temperature is High3330
Machine Does Not Turn (For Steering Wheel Spec)3333
Machine Does Not Turn (Joystick Steering Specification)3335
Turning Response is Unsatisfactory (For Steering Wheel Specification)3337
Turning Response is Unsatisfactory (Joystick Steering Specification)3339
Steering Wheel is Heavy to Operate3341
Machine Sways or Large Shocks are Made While Machine Turns (For Steering Wheel Specification)3342
Machine Sways or Large Shocks are Made While Machine Turns (Joystick Steering Specification)3344
Turning Radius is Different on the Left and Right3346
Wheel Brakes Do Not Operate or are Weak3347
Wheel Brakes are Not Released or Drag3349
Parking Brake Does Not Operate or is Weak3350
Parking Brake is Not Released or Drags3351
Boom Does Not Rise3353
Boom Moves Slow or Lacks Lifting Force3355
Rising Boom Slows Down at Specified Height3357
Lift Cylinders Can Not Hold Bucket on Ground3358
Hydraulic Drift of Boom is Large3360
Boom Moves Up and Down During Operation3361
Bucket Does Not Tilt Back3362
Bucket Moves Slow or Lacks Tilt-Back Force3364
Bucket Slows Down During Tilt Back Operation3366
Bucket Cylinder Does Not Hold Bucket on Ground3367
Hydraulic Drift of Bucket is Large3369
Bucket Tilts Back and Forth When You Carry Load (Work Equipment Valve is in Hold)3370
Boom and Bucket Control Levers Do Not Move Smoothly and are Heavy to Move3371
Engine Speed Drops Largely or Engine Stops When You Operate Work Equipment3372
Large Shocks are Made When Work Equipment Starts to Move and Stops3373
When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves3376
ECSS Does Not Operate and Machine Pitches and Bounces3377
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)3378
Unusual Noise is Heard from Around Fan3380
Troubleshooting of Engine (S-Mode)3381
Information Shown in Troubleshooting Table (S-Mode)3381
Engine Does Not Crank When Starting Switch is Turned to Start Position3382
Engine Cranks but No Exhaust Smoke Comes Out3383
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)3384
Engine Startability is Unsatisfactory3385
Engine Does Not Pick Up Smoothly3387
Engine Stops During Operation3389
Engine Does Not Rotate Smoothly3391
Engine Lacks Output (or Lacks Power)3392
KDPF Becomes Clogged in a Short Time3394
Engine Oil Consumption is Excessive3396
Engine Oil Becomes Dirty Quickly3397
Fuel Consumption is Excessive3398
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)3399
Engine Oil Pressure Drops3400
Fuel Mixes Into Engine Oil3402
Water Mixes Into Engine Oil (Milky)3403
Coolant Temperature Increases Too High (Overheat)3404
Unusual Noise is Heard3405
Vibration is Excessive3406
Air Cannot be Bled from Fuel Circuit3407
Active Regeneration is Done Frequently3408
Active Regeneration Continues Long3410
White Smoke is Exhausted During Active Regeneration3411
DEF Consumption is Excessive3412
There is an Unusual Smell (Irritating Odor)3414
Foreign Materials Enter DEF (DEF Increases)3415
Troubleshooting for Auto-Greasing System3416
Outline of Failure Display3416
Troubleshooting for FCS3417
Troubleshooting for Auto-Greasing Pump3418
Replacement of Pump Element3421
Troubleshooting for Grease Supply System3422
Replace Auto-Greasing Controller3424
Assembly procedure when disassembled in troubleshooting3425
Troubleshooting for RDS Load Meter System3426
Outline of Failure Display3426
How to Show Diagnostics Screen3427
Troubleshooting for RDS Load Meter3428
50 Disassembly and Assembly3431
Table of Contents3432
Precautions Before Work3437
Abbreviation List3438
Related Information on Disassembly and Assembly3444
How to Read This Manual3444
Coating Materials List3446
Special Tool List3451
Sketches of Special Tools3468
Engine and Cooling System3496
Remove and Install Supply Pump Assembly3496
How to Remove Supply Pump Assembly3496
How to Install Supply Pump Assembly3500
Remove and Install Injector Assembly3506
How to Remove Injector Assembly3506
How to Install Injector Assembly3511
Remove and Install Fuel Doser Assembly3517
How to Remove Fuel Doser Assembly3517
How to Install Fuel Doser Assembly3518
Remove and Install Cylinder Head Assembly3521
How to Remove Cylinder Head Assembly3522
How to Install Cylinder Head Assembly3534
Remove and Install EGR Valve Assembly3553
How to Remove EGR Valve Assembly3553
How to Install EGR Valve Assembly3553
Remove and Install EGR Cooler Assembly3555
How to Remove EGR Cooler Assembly3555
How to Install EGR Cooler Assembly3557
Remove and Install Starter Assembly3561
How to Remove Starting Motor Assembly3561
How to Install Starting Motor Assembly3562
Remove and Install Air Conditioner Compressor Belt3564
How to Remove Air Conditioner Compressor Belt3564
How to Install Air Conditioner Compressor Belt3566
Remove and Install Alternator Belt3569
How to Remove Alternator Belt3569
How to Install Alternator Belt3571
Remove and Install Automatic Tensioner3573
How to Remove Automatic Tensioner3573
How to Install Automatic Tensioner3573
Remove and Install Radiator Assembly3574
How to Remove Radiator Assembly3575
How to Install Radiator Assembly3580
Remove and Install Cooling Fan and Fan Motor Assembly3586
How to Remove Cooling Fan and Fan Motor Assembly3586
How to Install Cooling Fan and Fan Motor Assembly3590
Remove and Install Hydraulic Oil Cooler Assembly3593
How to Remove Hydraulic Oil Cooler Assembly3593
How to Install Hydraulic Oil Cooler Assembly3596
Remove and Install Aftercooler Assembly3599
How to Remove Aftercooler Assembly3599
How to Install Aftercooler Assembly3603
Remove and Install Power Train Oil Cooler Assembly3609
How to Remove Power Train Oil Cooler Assembly3609
How to Install Power Train Oil Cooler Assembly3616
Remove and Install Engine, Torque Converter, and Transmission Assembly3623
How to Remove Engine, Torque Converter, and Transmission Assembly3624
How to Install Engine, Torque Converter, and Transmission Assembly3639
Disconnect and Connect Engine, Torque Converter, and Transmission Assembly3654
How to Disconnect Engine, Torque Converter, and Transmission Assembly3654
How to Connect Engine, Torque Converter, and Transmission Assembly3655
Remove and Install Engine Front Oil Seal3656
How to Remove Engine Front Oil Seal3656
How to Install Engine Front Oil Seal3658
Remove and Install Engine Rear Oil Seal3661
How to Remove Engine Rear Oil Seal3661
How to Install Engine Rear Oil Seal3662
Remove and Install Engine Hood Assembly3668
How to Remove Engine Hood Assembly3668
How to Install Engine Hood Assembly3675
Remove and Install KDPF Assembly3681
How to Remove KDPF Assembly3683
How to Install KDPF Assembly3695
Disassemble and Assemble KDPF Assembly3709
How to Disassemble KDPF Assembly3709
How to Assemble KDPF Assembly3713
Remove and Install KDPF and SCR Assembly3718
How to Remove KDPF and SCR Assembly3719
How to Install KDPF and SCR Assembly3728
Remove and Install Bellows Pipe Assembly3738
How to Remove Bellows Pipe Assembly3738
How to Install Bellows Pipe Assembly3743
Remove and Install Fuel Tank Assembly3751
How to Remove Fuel Tank Assembly3751
How to Install Fuel Tank Assembly3756
Remove and Install DEF Tank Assembly3760
How to Remove DEF Tank Assembly3760
How to Install DEF Tank Assembly3764
Remove and Install DEF Tank Sensor Flange Assembly3767
How to Remove DEF Tank Sensor Flange Assembly3768
How to Install DEF Tank Sensor Flange Assembly3773
Remove and Install DEF Tank Sensor3777
How to Remove DEF Tank Sensor3777
How to Install DEF Tank Sensor3778
Remove and Install DEF Tank Strainer3785
How to Remove DEF Tank Strainer3785
How to Install DEF Tank Strainer3785
Remove and Install SCR Assembly3787
How to Remove SCR Assembly3788
How to Install SCR Assembly3798
Remove and Install KCCV Assembly3811
How to Remove KCCV Assembly3811
How to Install KCCV Assembly3813
Remove and Install VGT Assembly3815
How to Remove VGT Assembly3815
How to Install VGT Assembly3822
Remove and Install DEF Mixing Tube3830
How to Remove DEF Mixing Tube3830
How to Install DEF Mixing Tube3837
Remove and Install DEF Injector3846
How to Remove DEF Injector3846
How to Install DEF Injector3850
Remove and Install DEF Pump3854
How to Remove DEF Pump3854
How to Install DEF Pump3857
Remove and Install DEF Hose3860
How to Remove DEF Hose3860
How to Install DEF Hose3870
Remove and Install Air Cleaner Assembly3881
How to Remove Air Cleaner Assembly3881
How to Install Air Cleaner Assembly3882
Remove and Install Air Conditioner Compressor Assembly3884
How to Remove Air Conditioner Compressor Assembly3884
How to Install Air Conditioner Compressor Assembly3885
Remove and Install Air Conditioner Condenser Assembly3887
How to Remove Air Conditioner Condenser Assembly3887
How to Install Air Conditioner Condenser Assembly3888
Power Train3890
Disassemble and Assemble Torque Converter Assembly3890
How to Disassemble Torque Converter Assembly3890
How to Assemble Torque Converter Assembly3895
Disassemble and Assemble Transmission Assembly3902
How to Disassemble Transmission Assembly3904
How to Assemble Transmission Assembly3922
Disassemble and Assemble Transmission Clutch Pack Assembly3949
How to Disassemble Transmission Clutch Pack Assembly3950
How to Assemble Transmission Clutch Pack Assembly3966
Remove and Install Front Axle Assembly3986
How to Remove Front Axle Assembly3986
How to Install Front Axle Assembly3988
Remove and Install Rear Axle Assembly3990
How to Remove Rear Axle Assembly3990
How to Install Rear Axle Assembly3997
Disassemble and Assemble Axle Housing Assembly4005
How to Disassemble Axle Housing Assembly4006
How to Assemble Axle Housing Assembly4011
Disassemble and Assemble Differential Assembly4020
How to Disassemble Differential Assembly4021
How to Assemble Differential Assembly4030
Steering System4049
Remove and Install Steering Valve Assembly4049
How to Remove Steering Valve Assembly4049
How to Install Steering Valve Assembly4052
Brake System4055
Remove and Install Parking Brake Disc and Plate4055
How to Remove Parking Brake Disc and Plate4055
How to Install Parking Brake Disc and Plate4059
Undercarriage and Frame4063
Remove and Install Center Hinge Pin4063
How to Remove Center Hinge Pin4063
How to Install Center Hinge Pin4069
Remove and Install Counterweight Assembly4076
How to Remove Counterweight Assembly4076
How to Install Counterweight Assembly4078
Remove and Install Full-Length Fender Assembly4081
How to Remove Full-Length Fender Assembly4081
How to Install Full-Length Fender Assembly4082
Hydraulic System4083
Remove and Install Hydraulic Tank Assembly4083
How to Remove Hydraulic Tank Assembly4083
How to Install Hydraulic Tank Assembly4088
Remove and Install Work Equipment Pump and Cooling Fan Pump Assembly4094
How to Remove Work Equipment Pump and Cooling Fan Pump Assembly4094
How to Install Work Equipment Pump and Cooling Fan Pump Assembly4097
Remove and Install Steering Pump and Power Train Pump Assembly4099
How to Remove Steering Pump and Power Train Pump Assembly4099
How to Install Steering Pump and Power Train Pump Assembly4102
Remove and Install Control Valve Assembly4105
How to Remove Control Valve Assembly4105
How to Install Control Valve Assembly4109
Disassemble and Assemble Hydraulic Cylinder Assembly4113
How to Disassemble Hydraulic Cylinder Assembly4114
How to Assemble Hydraulic Cylinder Assembly4117
Work Equipment4123
Remove and Install Work Equipment Assembly4123
How to Remove Work Equipment Assembly4123
How to Install Work Equipment Assembly4128
CAB Related Parts4134
Remove and Install Operator Cab Assembly4134
How to Remove Operator Cab Assembly4134
How to Install Operator Cab Assembly4140
Remove and Install Operator Cab Glass (Adhered Glass)4147
How to Remove Operator Cab Glass (Adhered Glass)4147
How to Install Operator Cab Glass (Adhered Glass)4148
Remove and Install Air Conditioner Unit Assembly4157
How to Remove Air Conditioner Unit Assembly4157
How to Install Air Conditioner Unit Assembly4168
Remove and Install Operator Seat Assembly4178
How to Remove Operator Seat Assembly4178
How to Install Operator Seat Assembly4180
How to Remove and Install Seat Belt4182
How to Remove Seat Belt4182
How to Install Seatbelt4182
Electrical System4184
Remove and Install Engine Controller Assembly4184
How to Remove Engine Controller Assembly4184
How to Install Engine Controller Assembly4187
Remove and Install Work Equipment Controller Assembly4190
How to Remove Work Equipment Controller Assembly4190
How to Install Work Equipment Controller Assembly4191
Remove and Install Transmission Controller Assembly4194
How to Remove Transmission Controller Assembly4194
How to Install Transmission Controller Assembly4195
Remove and Install Monitor Controller Assembly4196
How to Remove Monitor Controller Assembly4196
How to Install Monitor Controller Assembly4198
Remove and Install Machine Monitor Assembly4201
How to Remove Machine Monitor Assembly4201
How to Install Machine Monitor Assembly4202
Remove and Install Mass Air Flow and Temperature Sensor4205
How to Remove Mass Air Flow and Temperature Sensor4205
How to Install Mass Air Flow and Temperature Sensor4206
Remove and Install KCCV Crankcase Pressure Sensor4207
How to Remove KCCV Crankcase Pressure Sensor4207
How to Install KCCV Crankcase Pressure Sensor4208
Remove and Install KDPF Temperature Sensor4210
How to Remove KDPF Temperature Sensor4210
How to Install KDPF Temperature Sensor4215
Remove and Install KDPF Differential Pressure Sensor4220
How to Remove KDPF Differential Pressure Sensor4220
How to Install KDPF Differential Pressure Sensor4224
Remove and Install SCR Temperature Sensor4229
How to Remove SCR Temperature Sensor4229
How to Install SCR Temperature Sensor4234
Remove and Install Ammonia Sensor4239
How to Remove Ammonia Sensor4239
How to Install Ammonia Sensor4243
Remove and Install SCR Outlet NOx Sensor4248
How to Remove SCR Outlet NOx Sensor4248
How to Install SCR Outlet NOx Sensor4253
Remove and Install KOMTRAX Terminal Assembly4257
How to Remove KOMTRAX Terminal Assembly4257
How to Install KOMTRAX Terminal Assembly4258
Remove and Install Gateway Function Controller Assembly4259
How to Remove Gateway Function Controller Assembly4259
How to Install Gateway Function Controller Assembly4260
Remove and Install Communication Terminal4261
How to Remove Communication Terminal4261
How to Install Communication Terminal4266
60 Maintenance Standard4273
Table of Contents4274
Abbreviation List4275
Engine and Cooling System4281
Maintenance Standard for Engine Mount4281
Maintenance Standard for Brake and Cooling Fan Pump4282
Maintenance Standard for Servo Valve of Brake and Cooling Fan Pump4284
Maintenance Standard for Cooling Fan Motor4285
Power Train4287
Maintenance Standard for Drive Shaft4287
Maintenance Standard for Torque Converter4288
Maintenance Standard for Lockup Clutch ECMV4290
Maintenance Standard for Transmission4291
Maintenance Standard for F, 1st Clutch4297
Maintenance Standard for R, 2nd Clutch4299
Maintenance Standard for 3rd, 4th Clutch4301
Maintenance Standard for Transmission Control Valve4303
Maintenance Standard for Forward and Reverse Clutch ECMV and 1st, 2nd Clutch ECMV4305
Maintenance Standard for 3rd, 4th Clutch ECMV4306
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve4307
Maintenance Standard for Front Axle4308
Maintenance Standard for Rear Axle4309
Maintenance Standard for Front Conventional Differential4310
Maintenance Standard for Rear Conventional Differential4313
Maintenance Standard for Front Limited Slip Differential4316
Maintenance Standard for Rear Limited Slip Differential4318
Maintenance Standard for Final Drive4320
Steering System4323
Maintenance Standard for Steering Column4323
Maintenance Standard for Steering Pump4324
Maintenance Standard for Servo Valve of Steering Pump4327
Maintenance Standard for Steering Valve4328
Maintenance Standard for Steering Cylinder4330
Maintenance Standard for Secondary Steering Pump4332
Brake System4333
Maintenance Standard for Charge Valve4333
Maintenance Standard for Brake Circuit Accumulator4335
Maintenance Standard for Slack Adjuster4336
Maintenance Standard for Front Brake4337
Maintenance Standard for Rear Brake4338
Maintenance Standard for Parking Brake4339
Maintenance Standard for Parking Brake Solenoid Valve4341
Maintenance Standard for Flow Priority Valve4342
Maintenance Standard for Brake Cooling Pump4343
Maintenance Standard for Brake Cooling Strainer4344
Undercarriage and Frame4345
Maintenance Standard for Frame, Axle Mount and Center Hinge Pin4345
Hydraulic System4350
Maintenance Standard for Hydraulic Tank4350
Maintenance Standard for Work Equipment Pump4352
Maintenance Standard for Power Train Charge Pump and Power Train Lubrication Pump4354
Maintenance Standard for Control Valve4355
Maintenance Standard for Work Equipment Lock Solenoid Valve4364
Work Equipment4365
Maintenance Standard for Work Equipment Linkage4365
Maintenance Standard for Bucket4369
Maintenance Standard for Lift Cylinder4370
Maintenance Standard for Bucket Cylinder4371
80 Appendix4373
Table of Contents4374
Precautions Before Work4376
Abbreviation List4377
Air Conditioner System4383
Precautions for Refrigerant4383
Air Conditioner Component4384
Specifications of Air Conditioner4386
Structure and Function of Refrigeration Cycle4387
Outline of Refrigeration Cycle4388
Component Parts of Air Conditioner System4390
Air Conditioner Unit4390
Configuration Diagram of Air Conditioner Unit4390
Function of Air Conditioner Unit4391
Component Parts of Air Conditioner Unit4392
Function of Evaporator as Air Conditioner Unit Component4392
Function of Inside Air Temperature Sensor as Air Conditioner Unit Component4392
Function of Blower Amplifier as Air Conditioner Unit Component4393
Function of Blower OFF Relay as Air Conditioner Unit Component4393
Function of Compressor Clutch Relay as Air Conditioner Unit Component4393
Function of Heater Core as Air Conditioner Unit Component4393
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component4393
Function of Servo Motor as Air Conditioner Unit Component4393
Function of Expansion Valve as Air Conditioner Unit Component4394
Function of Dual Pressure Switch4394
Air Conditioner Controller4395
Structure of Air Conditioner Controller4395
Compressor4396
Structure of Compressor4396
Specifications of Compressor4396
Function of Compressor4396
Condenser4397
Structure of Condenser4397
Specifications of Condenser4397
Function of Condenser4397
Receiver Drier4398
Structure of Receiver Dryer4398
Specifications of Receiver Dryer4398
Function of Receiver Dryer4398
Air Conditioner Related Sensors4399
Function of Sunlight Sensor4399
Function of Outside Air Temperature Sensor4399
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner4400
Circuit Diagram and Configuration of Connector Pins of Air Conditioner4402
System Diagram of Air Conditioner4405
Input and Output Signals of Air Conditioner Controller4406
Function of Air Conditioner Controller4407
Locations of Air Conditioner Parts and Layout of Connectors4408
Examine Air Conditioner with Self-Diagnosis Function4414
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor4415
Examine Temperature Control Function4416
How to Examine Temperature Control Function4416
Examine Vent (Mode) Changeover4418
How to Examine Vent (Mode) Changeover4418
Examine Fresh/Recirc Air Changeover4420
How to Examine Fresh/Recirc Air Changeover4420
Examine Evaporator Temperature Sensor4422
Examine Relay4424
How to Examine Relay4424
Air Conditioner Troubleshooting Chart 14426
Air Conditioner Troubleshooting Chart 24427
Information Shown in Troubleshooting Table4430
Failure Code [879AKA]4431
Failure Code [879AKB]4434
Failure Code [879BKA]4437
Failure Code [879BKB]4440
Failure Code [879CKA]4443
Failure Code [879CKB]4446
Failure Code [879DKZ]4449
Failure Code [879EMC]4452
Failure Code [879FMC]4457
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)4462
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)4465
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)4468
Troubleshooting for Fresh/Recirc Air Changeover4472
Troubleshooting by Gauge Pressure4474
Connect Service Tool4477
How to Connect Service Tool4478
Precautions for Disconnection and Connection of Air Conditioner Piping4479
Handle Compressor Oil4481
90 Circuit Diagrams4483
Table of Contents4484
Abbreviation List4486
Hydraulic Circuit Diagram4492
Symbols Used in Hydraulic Circuit Diagram4492
Hydraulic Circuit Diagram (For Steering Wheel Spec)4497
Hydraulic Circuit Diagram (For Joystick Steering Spec)4499
Power Train Hydraulic Circuit Diagram4501
Hydraulic Oil Pressure of Brake Cooling System4503
Hydraulic Auto-Greasing Diagram4507
Electrical Circuit Diagram4509
Symbols Used in Electric Circuit Diagram4509
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (1/9)4513
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (2/9)4515
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (3/9)4517
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (4/9)4519
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (5/9)4521
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (6/9)4523
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (7/9)4525
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (8/9)4527
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (9/9)4529
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (1/9)4531
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (2/9)4533
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (3/9)4535
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (4/9)4537
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (5/9)4539
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (6/9)4541
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (7/9)4543
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (8/9)4545
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (9/9)4547
Electrical Circuit Diagram of Floor (For North America) (Machine with KOMTRAX Terminal) (1/8)4549
Electrical Circuit Diagram of Floor (For North America) (Machine with KOMTRAX Terminal) (2/8)4551
Electrical Circuit Diagram of Floor (For North America) (Machine with KOMTRAX Terminal) (3/8)4553
Electrical Circuit Diagram of Floor (For North America) (Machine with KOMTRAX Terminal) (4/8)4555
Electrical Circuit Diagram of Floor (For North America) (Machine with KOMTRAX Terminal) (5/8)4557
Electrical Circuit Diagram of Floor (For North America) (Machine with KOMTRAX Terminal) (6/8)4559
Electrical Circuit Diagram of Floor (For North America) (Machine with KOMTRAX Terminal) (7/8)4561
Electrical Circuit Diagram of Floor (For North America) (Machine with KOMTRAX Terminal) (8/8)4563
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (1/9)4565
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (2/9)4567
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (3/9)4569
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (4/9)4571
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (5/9)4573
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (6/9)4575
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (7/9)4577
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (8/9)4579
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (9/9)4581
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (1/9)4583
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (2/9)4585
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (3/9)4587
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (4/9)4589
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (5/9)4591
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (6/9)4593
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (7/9)4595
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (8/9)4597
Electrical Circuit Diagram of Floor (For North America) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (9/9)4599
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (1/9)4601
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (2/9)4603
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (3/9)4605
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (4/9)4607
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (5/9)4609
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (6/9)4611
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (7/9)4613
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (8/9)4615
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (9/9)4617
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (1/10)4619
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (2/10)4621
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (3/10)4623
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (4/10)4625
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (5/10)4627
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (6/10)4629
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (7/10)4631
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (8/10)4633
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (9/10)4635
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011) (10/10)4637
RDS Load Meter System Electrical Circuit Diagram4639
Electrical Circuit Diagram (Brake Cooling System)4641
Index4643
S.M 29/12/24
