Komatsu WHEEL LOADER WA480-8E0 Shop Manual SEN06754-08 – PDF
$36.95
Komatsu WHEEL LOADER WA480-8E0 Shop Manual SEN06754-08 – PDF DOWNLOAD
SERIAL NUMBERS 100439 and up
Description
Komatsu WHEEL LOADER WA480-8E0 Shop Manual SEN06754-08 – PDF DOWNLOAD
FILE DETAILS:
Komatsu WHEEL LOADER WA480-8E0 Shop Manual SEN06754-08 – PDF DOWNLOAD
Language : English
Pages :4272
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WHEEL LOADER WA480-8E0 Shop Manual SEN06754-08 – PDF DOWNLOAD
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 WA480-8E0 Shop Manual SEN06754-08 – PDF DOWNLOAD
Cover 2
00 Index and Foreword 3
Index 4
Abbreviation List 28
Foreword, Safety, Basic Information 34
How to Read the Shop Manual 34
Safety Notice for Operation 36
Precautions to Prevent Fire 44
Procedures If Fire Occurs 46
Precautions for Disposing of Waste Materials 47
Procedures for Exhaust Gas Regulations 48
Precautions for DEF 49
General Character and Precautions for Handling 49
Precautions for Adding 49
Precautions for Storage 49
Precautions for Fire Hazard and Leakage 49
Other Precautions 49
Store DEF 50
Precautions When You Handle Hydraulic Equipment 51
Precautions When You Disconnect and Connect Pipings 54
Precautions When You Handle Electrical Equipment 61
Precautions When You Handle Fuel System Equipment 63
Precautions When You Handle Intake System Equipment 64
Practical Use of KOMTRAX 65
Disconnect and Connect Push-Pull Type Coupler 66
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 66
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 67
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 68
Precautions for Disconnection and Connection of Connectors 70
How to Disconnect and Connect Deutsch Connector 74
How to Disconnect and Connect Slide Lock Type Connector 75
How to Disconnect and Connect Connector with Lock to Pull 77
How to Disconnect and Connect Connector with Lock to Push 78
How to Disconnect and Connect Connector with Housing to Rotate 80
How to Read the Codes for Electric Cable 81
Explanation of Terms for Maintenance Standard 85
Standard Tightening Torque Table 88
Conversion Table 95
01 Specifications 101
Table of Contents 102
Abbreviation List 103
Specifications 109
Specification Drawing 109
Specification Drawing: WA480-8E0 109
Specifications 111
Specification: WA480-8E0 111
Weight Table 116
Weight Table: WA480-8E0 116
Fuel, Coolant, Lubricants (For North America) 118
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 118
Fuel, Coolant, Lubricants (For European Union) 120
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 120
10 Structure and Function 123
Table of Contents 124
Abbreviation List 129
Urea SCR System 135
Layout Drawing of Urea SCR System 135
Urea SCR System Diagram 137
Function of Urea SCR System 138
Function of DEF System 138
Inducement Strategy 141
Component Parts of Urea SCR System 155
DEF Mixing Tube 155
SCR Assembly 156
DEF Tank 158
DEF Pump 160
DEF Injector 161
DEF Hose 162
DEF Tank Heating Valve 163
Boot-up System 164
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) 164
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) 166
System Operating Lamp System 168
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 168
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) 168
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 168
Function of System Operating Lamp System (Machine with Gateway Function Controller) 169
Battery Disconnect Switch 171
Function of Battery Disconnect Switch 171
Preheating System 172
System Diagram of Preheating System 172
Function of Automatic Preheating System 172
Operation of Automatic Preheating System 172
Function of Manual Preheating System 173
Operation of Manual Preheating System 173
Engine System 174
Layout Drawing of Engine System 174
Function of Engine System 175
Engine Control System 176
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) 176
System Diagram of Engine Control System (Machine with Gateway Function Controller) 177
Function of Engine Control System 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 188
EGR Valve 190
EGR Cooler 192
KCCV System 193
KCCV Ventilator 195
KDPF 197
Cooling System 202
Layout Drawing of Cooling System 202
Specifications of Cooling System 203
Cooling Fan Control System 204
System Diagram of Cooling Fan Control System 204
Function of Cooling Fan Control System 204
Component Parts of Cooling System 209
Brake and Cooling Fan Pump 209
Cooling Fan Motor 217
Control System 223
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 223
Layout Drawing of Control System (Machine with Gateway Function Controller) 225
Machine Monitor System 227
System Diagram of Machine Monitor System 227
Function of Machine Monitor System 227
Rearview Monitor System 229
System Diagram of Rearview Monitor System 229
Function of Rearview Monitor System 229
KOMTRAX System 230
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 230
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 230
Function of KOMTRAX System 231
Load Meter System 232
Load Meter System Diagram (Machine with KOMTRAX Terminal) 232
Load Meter System Diagram (Machine with Gateway Function Controller) 233
Function of Load Meter System 233
Component Parts of Control System 239
Machine Monitor 239
Switch Panel 261
Rearview Monitor 262
Rearview Camera 264
KOMTRAX Terminal 265
Gateway Function Controller 267
Communication Terminal 270
Transmission Controller 272
Work Equipment Controller 277
Monitor Controller 282
CAN Terminating Resistor 287
Engine Controller 288
Accelerator Pedal 295
Hydraulic System 297
Layout Drawing of Hydraulic System 297
CLSS 298
Structure of CLSS 298
Function of CLSS 299
Work Equipment Pump and Steering Pump Control System 302
Swash Plate Control Function of Work Equipment Pump and Steering Pump 302
Pickup Assistance Control Function When Engine Speed is Low 302
Overheat Prevention Function of Work Equipment Circuit 302
Component Parts of Hydraulic System 303
Hydraulic Tank 303
Work Equipment Pump 306
Steering Pump 324
Power Train Charge Pump and Power Train Lubrication Pump 337
Control Valve 338
Power Train System 373
Layout Drawing of Power Train System 373
Operation of Power Train System 376
Transmission Control System 377
Transmission Control System Diagram 377
Transmission Gear Shift Control System 379
Electric Modulation Function System Diagram 379
Electric Modulation Function 380
Gear Shift Display Function 380
Automatic Gear Shift Function 380
Shift Hold Function 381
Kickdown Function 381
Automatic Kickdown Function 382
Torque Converter Lockup Function 382
Hunting Prevention Function 383
Transmission Initial Learning and ECMV Current Adjustment Function 383
Shift Point Changing Function 383
4th Gear Speed Limitation Function 383
Transmission Protection Function 385
Protection Function When Travel Direction is Changed 385
Shift Down Protection Function 386
Engine Overrun Prevention Function 386
Maximum Speed Limitation Function 386
Neutralizer Function 387
Directional Selector Switch Control Function 388
Transmission Cut-off Function 390
Component Parts of Power Train System 392
Drive Shaft 392
Torque Converter 394
Lockup Clutch ECMV 398
Transmission 401
Transmission Control Valve 418
Forward and Reverse Clutch ECMV and 1st, 2nd Clutch ECMV 421
3rd and 4th Clutch ECMV 426
Main Relief Valve and Torque Converter Relief Valve 432
Axle 434
Conventional Differential 436
Limited Slip Differential 439
Final Drive 444
AJSS Knob 446
Combination Switch 447
Shift Hold Switch 451
Kickdown Switch 452
Work Equipment System 453
Layout Drawing of Work Equipment System 453
Work Equipment System Diagram (Applicable Machine: 100439 to 101011) 455
Work Equipment System Diagram (Applicable Machine: 101012 and Up) 457
Work Equipment Control System 459
Work Equipment Speed Pattern Control Function by Work Equipment Lever Stroke 459
Work Equipment Lever Detent Position and Work Equipment Startup Current Control Function 459
Work Equipment Lever Operating Function System Diagram 460
Work Equipment Lever Operation Function 461
Bucket Priority Control Function 461
Boom Stop Modulation Function 461
Work Equipment Neutral Lock System 463
Work Equipment Neutral Lock System Diagram 463
Function of Work Equipment Neutral Lock System 463
Remote Positioner System 465
Remote Bucket Positioner System Diagram 465
Function of Remote Bucket Positioner System 465
Remote Boom Positioner System Diagram 466
Function of Remote Boom Positioner System 466
Bucket Positioner and Boom Positioner 470
Structure of Bucket Positioner and Boom Positioner 470
Auto-Digging System 471
Auto-Digging System Diagram 471
Function of Auto-Digging System 471
ECSS 473
ECSS Diagram 473
Function of ECSS 473
Operation of ECSS 473
Component Parts of Work Equipment System 475
Work Equipment Lock Solenoid Valve 475
Pilot Circuit Accumulator 476
ECSS Circuit Accumulator 477
Work Equipment Electric Lever 479
Multifunction Mono-Lever 482
Steering System 483
Layout Drawing of Steering System 483
Secondary Steering System 486
Secondary Steering System Diagram 486
Function of Secondary Steering System 486
AJSS 488
Layout Drawing of AJSS 488
AJSS System Diagram 489
Function of AJSS 490
Neutralizer Function of AJSS 491
AJSS Neutral Interlock Function 491
AJSS Speed Sensing Steering Function 492
AJSS Turn Signal Pilot Lamp Control Function 493
Steering Column 494
Structure of Steering Column 494
Component Parts of Steering System 495
AJSS EPC Valve 495
Steering Lock Valve 496
Rotary Valve 497
Orbitrol Valve 500
Stop Valve 504
Steering Valve 505
Secondary Steering Pump 517
Secondary Steering Motor 518
Brake System 519
Layout Drawing of Brake System 519
Layout Drawing of Brake Cooling System 520
Parking Brake Control System 524
System Diagram of Parking Brake Control System 524
Operation of Parking Brake Control System 524
Brake Cooling Control System 526
Brake Cooling Control System Diagram 526
Function of Brake Cooling Control System 528
Component Parts of Brake System 529
Charge Valve 529
Parking Brake Solenoid Valve 534
Parking Brake Emergency Release Valve 536
Brake Circuit Accumulator 537
Brake Valve 539
Slack Adjuster 543
Brake 545
Parking Brake 548
Flow Priority Valve 550
Brake Cooling Motor 552
Brake Cooling Pump 553
Brake Cooling Pump Motor 554
Brake Cooling Oil Cooler 555
Brake Cooling Fan 558
Manual Type Valve 559
Auto-Greasing System 560
Layout Drawing of Auto-Greasing System 560
Specifications of Auto-Greasing System 561
Function of Auto-Greasing System 563
Auto-Greasing System 564
Auto-Greasing Pump 564
Undercarriage and Frame 565
Frame, Axle Mount and Center Hinge Pin 565
Structure of Frame, Axle Mount and Center Hinge Pin 565
Function of Frame, Axle Mount and Center Hinge Pin 565
Tires 567
Features of Radial Tire When Compared with Bias Tire 567
Structure of Radial Tire 567
Function of Radial Tire 568
Structure of Bias Tire 568
Function of Bias Tire 568
Work Equipment 569
Structure of Work Equipment 569
Structure of Bucket 570
CAB Related Parts 571
ROPS CAB 571
Structure of ROPS CAB (Machine with KOMTRAX Terminal) 571
Structure of ROPS CAB (Machine with Gateway Function Controller) 572
Function of ROPS CAB 572
20 Standard Value Table 573
Table of Contents 574
Abbreviation List 575
Standard Value Table for Engine 581
Standard Value Table for Engine: WA480-8E0 581
Standard Value Table for Machine 585
Standard Value Table for Machine: WA480-8E0 585
Machine Posture and Procedures to Measure Performance 610
30 Testing and Adjusting 615
Table of Contents 616
Precautions Before Work 620
Abbreviation List 621
Related Information on Testing and Adjusting 627
Differences In Machine Monitor Symbols 627
Tools for Testing and Adjusting 628
Sketch of Tools for Testing and Adjusting 638
Engine and Cooling System 640
Examine Engine Speed 640
How to Examine Engine Speed 640
Examine Boost Pressure 645
How to Examine Boost Pressure 645
Examine Exhaust Gas Temperature 648
How to Examine Exhaust Gas Temperature 648
Examine Exhaust Gas Color 650
How to Examine Exhaust Gas Color with the Handy Smoke Checker 650
How to Examine Exhaust Gas Color with Smoke Meter 651
Examine Mass Air Flow and Temperature Sensor 653
How to Examine Mass Air Flow and Temperature Sensor 653
Examine and Adjust Valve Clearance 655
How to Examine Valve Clearance 655
How to Adjust Valve Clearance 657
Examine Compression Pressure 658
How to Examine Compression Pressure 658
Examine Blowby Pressure 662
How to Examine Blowby Pressure 662
Examine Engine Oil Pressure 665
How to Examine Engine Oil Pressure on Machine Monitor 665
How to Examine Engine Oil Pressure by Testing Tool 665
Examine EGR Valve and VGT Oil Pressure 667
How to Examine EGR Valve and VGT Oil Pressure 667
Examine Fuel Pressure 668
How to Examine Fuel Pressure 668
Examine Fuel Return Rate and Leakage 670
How to Examine Fuel Return Rate and Leakage 671
Bleed Air from Fuel System 674
How to Bleed Air from Fuel System 675
Examine Fuel Circuit for Leakage 676
How to Examine Fuel System for Leakage 676
Handle Cylinder Cut-out Mode Operation 678
Handle No-Injection Cranking Operation 679
Examine KDPF, SCR and Muffler Stack for Looseness and Damage 680
How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage 680
Examine Installed Condition of Cylinder Heads and Manifolds 681
How to Examine Installed Condition of Cylinder Heads and Manifolds 681
Examine Engine Piping for Damage and Looseness 682
How to Examine Engine Piping for Damage and Looseness 682
Examine and Adjust Air Conditioner Compressor Belt Tension 683
How to Examine Air Conditioner Compressor Belt Tension 683
How to Adjust Air Conditioner Compressor Belt Tension 683
Examine Alternator Belt 685
How to Examine Alternator Belt 685
Examine Automatic Tensioner 687
How to Examine Automatic Tensioner 687
Clean Fuel Doser 690
How to Clean Fuel Doser 690
Write Injector Compensation Value to Engine Controller 692
How to Write Injector Compensation Value 692
Write Correction for Ash in Soot Accumulation to Engine Controller 699
How to Write Correction for Ash in Soot Accumulation to Engine Controller 699
Examine SCR Related Functions 700
Examine DEF Pump Raised Pressure 704
Examine Injection Volume from DEF Injector 707
Examine DEF Line Heater Relay 1 712
Examine DEF Line Heater Relay 2 716
Examine DEF Pump Heater Relay 720
Examine DEF Tank Heater Valve 724
Examine SCR Denitration Efficiency 728
Clean DEF Tank 732
How to Clean DEF Tank 732
Clean DEF Pump 736
How to Clean DEF Pump 736
Power Train 742
Examine and Adjust Power Train Oil Pressure 742
How to Examine Power Train Oil Pressure 744
How to Adjust Power Train Oil Pressure 762
Adjust Transmission Input Shaft Speed Sensor 764
How to Adjust Transmission Input Shaft Speed Sensor 764
Adjust Transmission Output Shaft Speed Sensor 766
How to Adjust Transmission Output Shaft Speed Sensor 766
Flush Torque Converter and Transmission Hydraulic Circuit 767
How to Flush Torque Converter and Transmission Hydraulic Circuit 767
Move Disabled Machine Due to Transmission Valve Failure 770
How to Move Disabled Machine Due to Transmission Valve Failure 771
Examine Drive Shaft for Looseness, Backlash, and Damage 774
How to Examine Drive Shaft for Looseness, Backlash, and Damage 774
Steering System 775
Examine Steering Wheel 775
How to Examine Steering Wheel 775
Examine and Adjust Steering Circuit Oil Pressure 777
How to Examine Steering Circuit Oil Pressure 777
How to Adjust Steering Circuit Oil Pressure 781
Bleed Air from Steering Cylinder Circuit 783
How to Bleed Air from Steering Cylinder Circuit 783
Examine and Adjust Steering Stop Valve 785
How to Examine Steering Stop Valve 785
How to Adjust Steering Stop Valve 785
Brake System 786
Release Remained Pressure in Brake Accumulator Circuit 786
How to Release Remained Pressure in Brake Accumulator Circuit 786
Examine Wheel Brake Oil Pressure 787
How to Examine Wheel Brake Oil Pressure 787
Examine and Adjust Accumulator Charge Pressure 789
How to Examine Accumulator Charge Pressure 789
How to Adjust Accumulator Charge Pressure 790
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas 791
How to Examine Accumulator Nitrogen Gas Pressure for Brake 791
How to Charge Accumulator Nitrogen Gas for Brake 794
How to Release Nitrogen Gas When You Discard Accumulator 798
Bleed Air from Brake Circuit 800
How to Bleed Air from Brake Circuit 800
Examine Brake Performance 804
How to Examine Brake Performance 804
Examine Brake Pedal 805
How to Examine Brake Pedal 805
Examine and Adjust Brake Pedal and Linkage 806
How to Examine Brake Pedal and Linkage 806
How to Adjust Brake Pedal and Linkage 806
Examine Pressure Decrease of Wheel Brake 807
How to Examine Pressure Decrease of Wheel Brake 808
Examine Wear of Wheel Brake Disc 810
How to Examine Wear of Wheel Brake Disc 810
Examine Parking Brake Oil Pressure 812
How to Examine Parking Brake Oil Pressure 812
Examine Parking Brake Performance 814
How to Examine Parking Brake Performance 814
Release Parking Brake Manually 815
How to Release Parking Brake Manually 815
Examine Wear Volume of Parking Brake Disc 818
How to Examine Wear Quantity of Parking Brake Disc 818
Hydraulic System 820
Release Remained Pressure from Work Equipment Circuit 820
How to Release Remained Pressure from Work Equipment Circuit 820
Examine and Adjust Work Equipment Oil Pressure 822
How to Examine Work Equipment Oil Pressure 822
How to Adjust Work Equipment Oil Pressure 826
Examine and Adjust Work Equipment EPC Oil Pressure 828
How to Examine Work Equipment EPC Oil Pressure 828
How to Adjust Work Equipment EPC Oil Pressure 831
Bleed Air from Work Equipment Circuit 833
How to Bleed Air from Work Equipment Circuit 833
Examine Cooling Fan Speed 834
How to Examine Cooling Fan Speed 834
Examine Cooling Fan Circuit Oil Pressure 835
How to Examine Cooling Fan Circuit Oil Pressure 835
Bleed Air from Cooling Fan Circuit 838
How to Bleed Air from Cooling Fan Circuit 838
Examine ECSS Accumulator Nitrogen Gas Pressure and Charge Accumulator with Nitrogen Gas 840
How to Examine ECSS Accumulator Nitrogen Gas Pressure 840
How to Charge ECSS Accumulator with Nitrogen Gas 842
Work Equipment 846
Examine and Adjust Bucket Potentiometer Lever 846
How to Examine Bucket Potentiometer Lever 846
How to Adjust Bucket Potentiometer Lever 846
Examine and Adjust Boom Potentiometer Lever 848
How to Examine Boom Potentiometer Lever 848
How to Adjust Boom Potentiometer Lever 848
CAB Related Parts 849
Examine Directional Lever 849
How to Examine Directional Lever 849
Examine Work Equipment Control Lever 850
How to Examine Work Equipment Control Lever 850
Examine AJSS Lever (For AJSS Spec) 853
How to Examine AJSS Lever 853
Examine Steering Lock Lever (AJSS Specification) 856
How to Examine Steering Lock Lever 856
Examine and Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor (AJSS Specifications) 857
How to Examine AJSS Lever Angle Sensor and AJSS Frame Angle Sensor 857
How to Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor 857
Examine and Adjust Steering Stopper Bolt (For AJSS Spec) 859
How to Examine Steering Stopper Bolt 859
How to Adjust Steering Stopper Bolt 859
Adjust Play of Operator Seat 861
How to Adjust Play of Operator Seat 861
Electrical System 862
Set and Adjust Each Equipment 862
Prepare for Transmission ECMV Current Adjustment 865
How to Adjust Transmission ECMV Current 866
How to Set and Reset Transmission Initial Learning 869
Set and Operate Machine Monitor 874
Operator Mode 878
Function to Show Technician Identification Status Screen 878
Function to Show Operator Identification Input Screen 878
Examine Function by LCD (Liquid Crystal Display) 879
Examine Function of Service Meter and Odometer 880
How to Set Usage Limitation and Change Maintenance Password 880
Service Mode 884
How to Operate Service Mode 884
How to See Pre-defined Monitoring Information 887
How to Examine Self-Define Monitor Information 900
Abnormality Record Menu 917
How to See Maintenance Record 922
Maintenance Mode Setting 924
How to Set Phone Number Entry 929
Default Menu 931
Diagnostic Tests Menu 947
Adjustment Menu 958
No-Injection Cranking Operation 995
KOMTRAX Settings Menu 998
How to Show Service Message1003
How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal)1005
How to Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal)1009
How to Start Up KOMTRAX System (Machine with Gateway Function Controller)1011
How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller)1017
Adjust Rearview Camera Angle1019
How to Adjust Rearview Camera Angle1019
Handle Voltage Circuit of Engine Controller1021
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal)1022
Handle Battery Disconnect Switch (Machine with Gateway Function Controller)1023
Examine Diodes1024
How to Examine Diodes by Digital Tester1024
How to Examine Diodes by Analog Tester1024
Auto-Greasing Device1025
Bleed the Air in Auto-Greasing System1025
How to Bleed the Air in Auto-Greasing System1025
Correspondence in Case of Grease Leakage from over Pressure Protection Valve1028
Correspondence in Case of Grease Leakage from over Pressure Protection Valve1028
Change Lubrication Time and Lubrication Interval1029
How to Change Lubrication Time and Lubrication Interval1030
Examine and Fill Auto-Greasing1032
How to Examine Auto-Greasing1032
How to Fill Auto-Greasing1033
Pm Clinic1034
Pm Clinic Service1034
Pm Clinic Check Sheet: WA480-8E01037
40 Troubleshooting1049
Table of Contents1050
Precautions Before Work1065
Abbreviation List1066
Related Information to Troubleshooting1072
General Troubleshooting Points1072
Troubleshooting Points for Urea SCR System1073
Sequence of Events in Troubleshooting1085
Checks Before Troubleshooting1087
Inspection Procedure Before Troubleshooting1089
Walk-Around Check1089
Test in Accordance with Testing Procedure1091
Examine Fuel Level and Type1091
Examine for Impure Ingredient in Fuel1091
Examine DEF Level and Type1092
Examine Fuel Prefilter1092
Examine Fuel Main Filter1094
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type1095
Examine Coolant Level (Reservoir Tank)1095
Examine Air Cleaner Clogging1096
Clean Outer Element1097
Replace Element1099
Examine Hydraulic Oil Level1100
Examine Hydraulic Oil Strainer1101
Examine Hydraulic Oil Filter1102
Examine Oil Level in Transmission Case1103
Examine Oil Level in Front Axle Case1105
Examine Oil Level in Rear Axle Case1106
Bleed Air from Fuel System1106
Bleed Air from Hydraulic System1106
How to Examine Electric Equipment1106
Preparation for Troubleshooting of Electrical System1113
Procedure for Troubleshooting1126
Symptom and Troubleshooting Numbers1128
Information Shown in Troubleshooting Table1133
Connector List and Layout (Machine with KOMTRAX Terminal)1135
Connector List and Layout (Machine with Gateway Function Controller)1162
Connector Contact Connection Table1191
T-Branch Box and T-Branch Adapter Table1231
Fuse Location Table (Machine with KOMTRAX Terminal)1237
Fuse Location Table (Machine with Gateway Function Controller)1241
Precautions When You Clean and Replace KDPF (KCSF and KDOC)1245
Prepare Troubleshoot Machine Monitor1249
Procedure to Make Harness Checker on Machine Monitor LCD Unit1251
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])1257
Failure Code Table1259
Troubleshooting by Failure Code (Display of Code)1284
Failure Code [1500L0]1284
Failure Code [15SAL1]1285
Failure Code [15SALH]1287
Failure Code [15SBL1]1289
Failure Code [15SBLH]1291
Failure Code [15SEL1]1293
Failure Code [15SELH]1295
Failure Code [15SFL1]1297
Failure Code [15SFLH]1299
Failure Code [15SGL1]1301
Failure Code [15SGLH]1303
Failure Code [15SHL1]1305
Failure Code [15SHLH]1307
Failure Code [2F00MA]1310
Failure Code [2F00MB]1314
Failure Code [2G42ZG]1317
Failure Code [2G43ZG]1319
Failure Code [879AKA]1321
Failure Code [879AKB]1323
Failure Code [879BKA]1325
Failure Code [879BKB]1327
Failure Code [879CKA]1329
Failure Code [879CKB]1331
Failure Code [879DKZ]1333
Failure Code [879EMC]1335
Failure Code [879FMC]1338
Failure Code [989A00]1341
Failure Code [989L00]1342
Failure Code [989M00]1343
Failure Code [989N00]1344
Failure Code [A1U0N3]1345
Failure Code [A1U0N4]1347
Failure Code [AA10NX]1349
Failure Code [AB00KE]1351
Failure Code [AB00KY]1353
Failure Code [AQ10N3]1355
Failure Code [AS00N3]1357
Failure Code [AS00R2]1359
Failure Code [AS00R3]1360
Failure Code [AS00R4]1361
Failure Code [AS00R5]1362
Failure Code [AS00R6]1363
Failure Code [AS00ZK]1364
Failure Code [AS10KM]1365
Failure Code [AS10NR]1366
Failure Code [AS10NT]1367
Failure Code [B@BAZG]1368
Failure Code [B@BAZK]1369
Failure Code [B@BCNS]1371
Failure Code [B@BCQA]1372
Failure Code [B@BCZK]1374
Failure Code [B@C7NS]1376
Failure Code [B@CENS]1378
Failure Code [B@HANS]1379
Failure Code [CA115]1380
Failure Code [CA122]1381
Failure Code [CA123]1383
Failure Code [CA131]1385
Failure Code [CA132]1387
Failure Code [CA135]1390
Failure Code [CA141]1392
Failure Code [CA144]1394
Failure Code [CA145]1396
Failure Code [CA153]1398
Failure Code [CA154]1401
Failure Code [CA187]1404
Failure Code [CA221]1406
Failure Code [CA222]1408
Failure Code [CA227]1410
Failure Code [CA234]1411
Failure Code [CA238]1412
Failure Code [CA239]1414
Failure Code [CA249]1416
Failure Code [CA256]1418
Failure Code [CA271]1420
Failure Code [CA272]1422
Failure Code [CA273]1423
Failure Code [CA274]1425
Failure Code [CA322]1426
Failure Code [CA323]1428
Failure Code [CA324]1430
Failure Code [CA325]1432
Failure Code [CA331]1434
Failure Code [CA332]1436
Failure Code [CA343]1438
Failure Code [CA351]1439
Failure Code [CA352]1440
Failure Code [CA356]1443
Failure Code [CA357]1445
Failure Code [CA386]1447
Failure Code [CA431]1448
Failure Code [CA432]1451
Failure Code [CA441]1455
Failure Code [CA442]1457
Failure Code [CA449]1458
Failure Code [CA451]1459
Failure Code [CA452]1461
Failure Code [CA515]1463
Failure Code [CA516]1465
Failure Code [CA553]1467
Failure Code [CA555]1468
Failure Code [CA556]1469
Failure Code [CA559]1470
Failure Code [CA595]1475
Failure Code [CA687]1476
Failure Code [CA689]1478
Failure Code [CA691]1480
Failure Code [CA692]1482
Failure Code [CA697]1484
Failure Code [CA698]1485
Failure Code [CA731]1486
Failure Code [CA778]1487
Failure Code [CA1117]1490
Failure Code [CA1664]1491
Failure Code [CA1669]1494
Failure Code [CA1673]1495
Failure Code [CA1677]1496
Failure Code [CA1678]1497
Failure Code [CA1682]1498
Failure Code [CA1683]1502
Failure Code [CA1684]1504
Failure Code [CA1686]1506
Failure Code [CA1691]1507
Failure Code [CA1694]1510
Failure Code [CA1695]1512
Failure Code [CA1696]1513
Failure Code [CA1712]1515
Failure Code [CA1713]1518
Failure Code [CA1714]1520
Failure Code [CA1715]1521
Failure Code [CA1776]1522
Failure Code [CA1777]1525
Failure Code [CA1843]1528
Failure Code [CA1844]1530
Failure Code [CA1879]1533
Failure Code [CA1881]1536
Failure Code [CA1883]1538
Failure Code [CA1885]1542
Failure Code [CA1887]1544
Failure Code [CA1921]1546
Failure Code [CA1922]1549
Failure Code [CA1923]1554
Failure Code [CA1924]1556
Failure Code [CA1925]1558
Failure Code [CA1927]1560
Failure Code [CA1928]1562
Failure Code [CA1942]1564
Failure Code [CA1963]1565
Failure Code [CA1977]1569
Failure Code [CA1993]1572
Failure Code [CA2185]1575
Failure Code [CA2186]1577
Failure Code [CA2249]1579
Failure Code [CA2265]1580
Failure Code [CA2266]1582
Failure Code [CA2271]1585
Failure Code [CA2272]1587
Failure Code [CA2349]1589
Failure Code [CA2353]1591
Failure Code [CA2357]1593
Failure Code [CA2381]1594
Failure Code [CA2382]1596
Failure Code [CA2383]1598
Failure Code [CA2386]1600
Failure Code [CA2387]1602
Troubleshooting Flowchart1606
Failure Code [CA2555]1607
Failure Code [CA2556]1609
Failure Code [CA2637]1611
Failure Code [CA2639]1613
Failure Code [CA2732]1616
Failure Code [CA2733]1618
Failure Code [CA2741]1620
Failure Code [CA2765]1621
Failure Code [CA2771]1622
Failure Code [CA2777]1628
Failure Code [CA2878]1631
Failure Code [CA2881]1634
Failure Code [CA2976]1637
Failure Code [CA3133]1639
Failure Code [CA3134]1641
Failure Code [CA3135]1643
Failure Code [CA3142]1647
Failure Code [CA3143]1648
Failure Code [CA3144]1649
Failure Code [CA3146]1651
Failure Code [CA3147]1652
Failure Code [CA3148]1653
Failure Code [CA3151]1655
Failure Code [CA3165]1661
Failure Code [CA3167]1663
Failure Code [CA3229]1666
Failure Code [CA3231]1668
Failure Code [CA3232]1670
Failure Code [CA3235]1674
Failure Code [CA3239]1676
Failure Code [CA3241]1679
Failure Code [CA3242]1682
Failure Code [CA3251]1685
Failure Code [CA3253]1687
Failure Code [CA3254]1690
Failure Code [CA3255]1693
Failure Code [CA3256]1697
Failure Code [CA3311]1699
Failure Code [CA3312]1701
Failure Code [CA3313]1704
Failure Code [CA3314]1705
Failure Code [CA3315]1706
Failure Code [CA3316]1709
Failure Code [CA3317]1710
Failure Code [CA3318]1711
Failure Code [CA3319]1714
Failure Code [CA3321]1715
Failure Code [CA3322]1717
Failure Code [CA3419]1720
Failure Code [CA3421]1722
Failure Code [CA3497]1724
Failure Code [CA3498]1725
Failure Code [CA3543]1726
Failure Code [CA3545]1733
Failure Code [CA3547]1735
Failure Code [CA3558]1736
Failure Code [CA3559]1738
Failure Code [CA3562]1740
Failure Code [CA3563]1742
Failure Code [CA3567]1745
Failure Code [CA3568]1748
Failure Code [CA3571]1754
Failure Code [CA3572]1756
Failure Code [CA3574]1758
Failure Code [CA3575]1760
Failure Code [CA3577]1762
Failure Code [CA3578]1764
Failure Code [CA3582]1766
Failure Code [CA3583]1774
Failure Code [CA3596]1776
Failure Code [CA3649]1779
Failure Code [CA3681]1781
Failure Code [CA3682]1786
Failure Code [CA3713]1792
Failure Code [CA3717]1795
Failure Code [CA3718]1796
Failure Code [CA3725]1797
Failure Code [CA3748]1800
Failure Code [CA3751]1803
Failure Code [CA3755]1805
Failure Code [CA3866]1807
Failure Code [CA3867]1811
Failure Code [CA3868]1814
Failure Code [CA3899]1818
Failure Code [CA3911]1820
Failure Code [CA3912]1824
Failure Code [CA3932]1826
Failure Code [CA3933]1828
Failure Code [CA3934]1830
Failure Code [CA3935]1833
Failure Code [CA3936]1835
Failure Code [CA4151]1837
Failure Code [CA4152]1841
Failure Code [CA4155]1845
Failure Code [CA4156]1847
Failure Code [CA4157]1850
Failure Code [CA4158]1852
Failure Code [CA4159]1853
Failure Code [CA4161]1854
Failure Code [CA4162]1857
Failure Code [CA4163]1860
Failure Code [CA4164]1862
Failure Code [CA4165]1864
Failure Code [CA4166]1866
Failure Code [CA4168]1868
Failure Code [CA4169]1871
Failure Code [CA4171]1873
Failure Code [CA4249]1876
Failure Code [CA4251]1878
Failure Code [CA4259]1880
Failure Code [CA4261]1883
Failure Code [CA4277]1886
Failure Code [CA4281]1890
Failure Code [CA4459]1893
Failure Code [CA4461]1895
Failure Code [CA4658]1898
Failure Code [CA4731]1902
Failure Code [CA4732]1903
Failure Code [CA4739]1904
Failure Code [CA4768]1905
Failure Code [CA4769]1907
Failure Code [CA4842]1910
Failure Code [CA4952] (Machine with KOMTRAX Terminal)1914
Failure Code [CA4952] (Machine with Gateway Function Controller)1916
Failure Code [CA5115]1918
Failure Code [CA5179]1921
Failure Code [CA5181]1923
Failure Code [CA5383]1925
Failure Code [D150KA]1927
Failure Code [D150KB]1929
Failure Code [D150KY]1931
Failure Code [D160KA]1933
Failure Code [D160KB]1935
Failure Code [D160KY]1937
Failure Code [D191KA]1939
Failure Code [D191KB]1942
Failure Code [D191KY]1945
Failure Code [D192KA]1947
Failure Code [D192KB]1949
Failure Code [D192KY]1951
Failure Code [D193KA]1952
Failure Code [D193KB]1954
Failure Code [D193KY]1956
Failure Code [D193MC] (Applicable Machine: 100001 to 101011)1958
Failure Code [D193MC] (Applicable Machine: 101012 and Up)1960
Failure Code [D19JKZ]1962
Failure Code [D1E6KA]1964
Failure Code [D1E6KB]1966
Failure Code [D1E6KY]1968
Failure Code [D5ZHKA]1970
Failure Code [D5ZHKB]1972
Failure Code [D5ZHKZ]1974
Failure Code [D5ZHL6]1977
Failure Code [D811MC] (Machine with KOMTRAX Terminal)1979
Failure Code [D811MC] (Machine with Gateway Function Controller)1980
Failure Code [D862KA] (Machine with KOMTRAX Terminal)1981
Failure Code [D862KA] (Machine with Gateway Function Controller)1982
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal)1983
Failure Code [D8ALKA] (Machine with Gateway Function Controller)1985
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal)1987
Failure Code [D8ALKB] (Machine with Gateway Function Controller)1989
Failure Code [D8AQK4] (Machine with KOMTRAX Terminal)1991
Failure Code [D8AQK4] (Machine with Gateway Function Controller)1992
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal)1993
Failure Code [D8AQKR] (Machine with Gateway Function Controller)1995
Failure Code [D8G1KT]1997
Failure Code [D8G6KT]1998
Failure Code [DAF0KT]1999
Failure Code [DAF0MB]2000
Failure Code [DAF0MC]2001
Failure Code [DAF3KK]2002
Failure Code [DAF8KB]2004
Failure Code [DAFDKB]2006
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal)2008
Failure Code [DAFGMC] (Machine with Gateway Function Controller)2009
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal)2010
Failure Code [DAFLKA] (Machine with Gateway Function Controller)2012
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal)2014
Failure Code [DAFLKB] (Machine with Gateway Function Controller)2016
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal)2018
Failure Code [DAFQKR] (Machine with Gateway Function Controller)2019
Failure Code [DAQ0KK]2020
Failure Code [DAQ0KT]2023
Failure Code [DAQ0MC]2024
Failure Code [DAQ1KA]2025
Failure Code [DAQ2KK]2027
Failure Code [DAQ2KT]2030
Failure Code [DAQ4KB]2033
Failure Code [DAQ9KQ]2035
Failure Code [DAQLKA] (Machine with KOMTRAX Terminal)2036
Failure Code [DAQLKA] (Machine with Gateway Function Controller)2038
Failure Code [DAQLKB] (Machine with KOMTRAX Terminal)2040
Failure Code [DAQLKB] (Machine with Gateway Function Controller)2042
Failure Code [DAQQKR]2044
Failure Code [DAQRKR]2045
Failure Code [DAQRMA]2046
Failure Code [DAZ9KQ]2047
Failure Code [DAZQKR]2048
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal)2049
Failure Code [DB2QKR] (Machine with Gateway Function Controller)2054
Failure Code [DB2RKR]2059
Failure Code [DB90KK] (Machine with KOMTRAX Terminal)2065
Failure Code [DB90KK](Machine with Gateway Function Controller)2068
Failure Code [DB90KT]2071
Failure Code [DB90MC]2072
Failure Code [DB91KA]2073
Failure Code [DB92KK] (Machine with KOMTRAX Terminal)2075
Failure Code [DB92KK] (Machine with Gateway Function Controller) (Applicable Machine: 100001 to 101011)2078
Failure Code [DB92KK] (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up)2081
Failure Code [DB92KT]2084
Failure Code [DB95KX] (Applicable Machine: 100001 to 101011)2087
Failure Code [DB95KX] (Applicable Machine: 101012 and Up)2091
Failure Code [DB96KX] (Applicable Machine: 100001 to 101011)2095
Failure Code [DB96KX] (Applicable Machine: 101012 and Up)2097
Failure Code [DB99KQ]2099
Failure Code [DB9LKA] (Machine with KOMTRAX Terminal)2100
Failure Code [DB9LKA] (Machine with Gateway Function Controller)2102
Failure Code [DB9LKB] (Machine with KOMTRAX Terminal)2104
Failure Code [DB9LKB] (Machine with Gateway Function Controller)2106
Failure Code [DB9QKR]2108
Failure Code [DB9RKR]2109
Failure Code [DB9RMA]2110
Failure Code [DBE5KX] (Applicable Machine: 100001 to 101011)2111
Failure Code [DBE5KX] (Applicable Machine: 101012 and Up)2113
Failure Code [DBE6KX]2115
Failure Code [DD1ALD]2117
Failure Code [DDAAL6]2119
Failure Code [DDB6L4]2121
Failure Code [DDD1LD]2124
Failure Code [DDK3KA]2126
Failure Code [DDK3KB]2129
Failure Code [DDK4KA]2132
Failure Code [DDK4KB]2135
Failure Code [DDK5L4]2137
Failure Code [DDK6KA]2139
Failure Code [DDK6KB]2142
Failure Code [DDKLKA] (Applicable Machine: 100001 to 101011)2145
Failure Code [DDKLKA] (Applicable Machine: 101012 and Up)2148
Failure Code [DDKLKB] (Applicable Machine: 100001 to 101011)2151
Failure Code [DDKLKB] (Applicable Machine: 101012 and Up)2153
Failure Code [DDNRKA]2155
Failure Code [DDNRKY] (Applicable Machine: 100001 to 101011)2158
Failure Code [DDNRKY] (Applicable Machine: 101012 and Up)2160
Failure Code [DDP5KA]2162
Failure Code [DDT0L4]2164
Failure Code [DDT4LD]2166
Failure Code [DDT9LD]2168
Failure Code [DDTALD]2170
Failure Code [DDW9LD]2172
Failure Code [DDWLLD]2174
Failure Code [DF10KA]2176
Failure Code [DF10KB]2179
Failure Code [DGF1KA]2182
Failure Code [DGF1KB]2184
Failure Code [DGH2KX]2186
Failure Code [DGR2KB]2188
Failure Code [DGR2KZ]2190
Failure Code [DGT1KA]2192
Failure Code [DGT1KB]2194
Failure Code [DH21KA]2196
Failure Code [DH21KB]2199
Failure Code [DHA4KA]2201
Failure Code [DHAAMA]2203
Failure Code [DHACMA]2205
Failure Code [DHPCKX]2207
Failure Code [DHPDKX]2210
Failure Code [DHT1KX]2213
Failure Code [DHT5KX]2216
Failure Code [DHT7KX]2219
Failure Code [DHT8KA]2222
Failure Code [DHT8KB]2225
Failure Code [DHT8ZG]2227
Failure Code [DHUDKA]2228
Failure Code [DHUDKB]2231
Failure Code [DJF1KA]2233
Failure Code [DK30KA]2235
Failure Code [DK30KY]2237
Failure Code [DK55KA]2239
Failure Code [DK55KY]2242
Failure Code [DK55L5]2244
Failure Code [DK59KA] (Applicable Machine: 100001 to 101011)2245
Failure Code [DK59KA] (Applicable Machine: 101012 and Up)2249
Failure Code [DK59KY] (Applicable Machine: 100001 to 101011)2253
Failure Code [DK59KY] (Applicable Machine: 101012 and Up)2257
Failure Code [DK59L8] (Applicable Machine: 100001 to 101011)2261
Failure Code [DK59L8] (Applicable Machine: 101012 and Up)2266
Failure Code [DK5AKA] (Applicable Machine: 100001 to 101011)2271
Failure Code [DK5AKA] (Applicable Machine: 101012 and Up)2275
Failure Code [DK5AKY] (Applicable Machine: 100001 to 101011)2279
Failure Code [DK5AKY] (Applicable Machine: 101012 and Up)2283
Failure Code [DK5BKA] (Applicable Machine: 100001 to 101011)2287
Failure Code [DK5BKA] (Applicable Machine: 101012 and Up)2291
Failure Code [DK5BKY] (Applicable Machine: 100001 to 101011)2295
Failure Code [DK5BKY] (Applicable Machine: 101012 and Up)2299
Failure Code [DK5BL8] (Applicable Machine: 100001 to 101011)2303
Failure Code [DK5BL8] (Applicable Machine: 101012 and Up)2308
Failure Code [DK5CKA] (Applicable Machine: 100001 to 101011)2313
Failure Code [DK5CKA] (Applicable Machine: 101012 and Up)2317
Failure Code [DK5CKY] (Applicable Machine: 100001 to 101011)2321
Failure Code [DK5CKY] (Applicable Machine: 101012 and Up)2325
Failure Code [DK5DKA] (Applicable Machine: 100001 to 101011)2329
Failure Code [DK5DKA] (Applicable Machine: 101012 and Up)2332
Failure Code [DK5DKY] (Applicable Machine: 100001 to 101011)2335
Failure Code [DK5DKY] (Applicable Machine: 101012 and Up)2338
Failure Code [DK5DL8] (Applicable Machine: 100001 to 101011)2341
Failure Code [DK5DL8] (Applicable Machine: 101012 and Up)2346
Failure Code [DK5EKA] (Applicable Machine: 100001 to 101011)2351
Failure Code [DK5EKA] (Applicable Machine: 101012 and Up)2354
Failure Code [DK5EKY] (Applicable Machine: 100001 to 101011)2357
Failure Code [DK5EKY] (Applicable Machine: 101012 and Up)2360
Failure Code [DK5FKA]2363
Failure Code [DK5FKY]2366
Failure Code [DK5FL8]2369
Failure Code [DK5GKA]2373
Failure Code [DK5GKY]2376
Failure Code [DKA0KA]2379
Failure Code [DKA0KY]2382
Failure Code [DKA0L0]2385
Failure Code [DKA1KA]2388
Failure Code [DKA1KY]2391
Failure Code [DKD0KA]2394
Failure Code [DKD0KY]2396
Failure Code [DKD0L8]2398
Failure Code [DLF1KA]2399
Failure Code [DLF1LC]2401
Failure Code [DLM3KA]2403
Failure Code [DLM3LC]2405
Failure Code [DLT3KA]2407
Failure Code [DLT3LC]2409
Failure Code [DPQ1KR]2411
Failure Code [DPQ2KR]2414
Failure Code [DPQ3KR]2417
Failure Code [DSJ0KR]2420
Failure Code [DT20KB] (Applicable Machine: 100001 to 101011)2423
Failure Code [DT20KB] (Applicable Machine: 101012 and Up)2425
Failure Code [DT22KB]2427
Failure Code [DT23KB]2429
Failure Code [DV00KB]2431
Failure Code [DW4PKA]2433
Failure Code [DW4PKB]2435
Failure Code [DW4PKY]2437
Failure Code [DW4QKA]2439
Failure Code [DW4QKB]2441
Failure Code [DW4QKY]2443
Failure Code [DW4RKA]2445
Failure Code [DW4RKB]2447
Failure Code [DW4RKY]2449
Failure Code [DW4SKA]2451
Failure Code [DW4SKB]2453
Failure Code [DW4SKY]2455
Failure Code [DW7BKA]2457
Failure Code [DW7BKB]2459
Failure Code [DW7BKY]2461
Failure Code [DWM1KA] (Applicable Machine: 100001 to 101011)2463
Failure Code [DWM1KA] (Applicable Machine: 101012 and Up)2465
Failure Code [DWM1KB] (Applicable Machine: 100001 to 101011)2467
Failure Code [DWM1KB] (Applicable Machine: 101012 and Up)2469
Failure Code [DWM1KY]2471
Failure Code [DWN6KA]2473
Failure Code [DWN6KB]2475
Failure Code [DWN6KY]2477
Failure Code [DWN8KA]2479
Failure Code [DWN8KB]2481
Failure Code [DWN8KY]2483
Failure Code [DX16KA]2485
Failure Code [DX16KB]2487
Failure Code [DX16KY]2489
Failure Code [DXA1KA]2491
Failure Code [DXA1KB]2493
Failure Code [DXA1KY]2495
Failure Code [DXANKA]2497
Failure Code [DXANKB]2499
Failure Code [DXANKY]2501
Failure Code [DXF0KA]2503
Failure Code [DXF0KB]2505
Failure Code [DXF0KY]2507
Failure Code [DXH1KA]2509
Failure Code [DXH1KB]2511
Failure Code [DXH1KY]2513
Failure Code [DXH4KA]2515
Failure Code [DXH4KB]2517
Failure Code [DXH4KY]2519
Failure Code [DXH5KA]2521
Failure Code [DXH5KB]2523
Failure Code [DXH5KY]2525
Failure Code [DXH6KA]2527
Failure Code [DXH6KB]2529
Failure Code [DXH6KY]2531
Failure Code [DXH7KA]2533
Failure Code [DXH7KB]2535
Failure Code [DXH7KY]2537
Failure Code [DXH8KA]2539
Failure Code [DXH8KB]2541
Failure Code [DXH8KY]2543
Failure Code [DXHHKA]2545
Failure Code [DXHHKB]2547
Failure Code [DXHHKY]2549
Failure Code [DXHJKA]2551
Failure Code [DXHJKB]2553
Failure Code [DXHJKY]2555
Failure Code [DXHKKA]2557
Failure Code [DXHKKB]2559
Failure Code [DXHKKY]2561
Failure Code [DXHLKA]2563
Failure Code [DXHLKB]2565
Failure Code [DXHLKY]2567
Failure Code [DXHMKA]2569
Failure Code [DXHMKB]2571
Failure Code [DXHMKY]2573
Failure Code [DY30MA]2575
Failure Code [DY30MC]2579
Failure Code [DY30ME]2584
Failure Code [F313KA]2586
Failure Code [F313KB]2588
Failure Code [F314KA]2589
Failure Code [F314KB]2591
Failure Code [F315KB]2593
Failure Code [F315KY]2595
Failure Code [F316KB]2597
Failure Code [F316KY]2599
Failure Code [F318KB]2601
Failure Code [F318KY]2603
Failure Code [F31AKB]2604
Failure Code [F31AKY]2606
Failure Code [F31BKB]2608
Failure Code [F31BKY]2610
Failure Code [F31CKB]2612
Failure Code [F31CKY]2614
Failure Code [F31DKB]2616
Failure Code [F31DKY]2618
Failure Code [F31EKB]2620
Failure Code [F31EKY]2622
Failure Code [FS10ZE]2624
Failure Code [LA00L3]2625
Troubleshooting of Electrical System (E-Mode)2626
Engine Does Not Start (Engine Does Not Crank)2626
Manual Preheating System Does Not Operate2635
Automatic Preheating System Does Not Operate2638
While Preheating is in Operation, Preheating Monitor Does Not Come On2641
The LCD Unit, LED Unit, and Meter Unit of the Machine Monitor Show Nothing2643
LCD Unit on Machine Monitor Shows Nothing2646
Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers)2649
LCD Screen on Machine Monitor Does Not Show Correctly2652
Meter Unit Display on Machine Monitor is Abnormal2655
Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal2658
LED Unit Lamp on Machine Monitor is Abnormal2661
Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly2663
Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate2666
Switch Panel Buzzer of Machine Monitor is Abnormal2669
Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally2672
DEF Level is Not Shown Correctly2673
Rearview Monitor Does Not Come On or Backlight Flickers2676
Rearview Monitor Images are Not Shown Clearly2679
Rearview Monitor Brightness Cannot be Adjusted2682
Night Mode Lamp of Rearview Monitor is Abnormal2686
Air Cleaner Clogging Indicator Lamp Does Not Come On2688
Radiator Coolant Level Caution Lamp Does Not Come On2690
Parking Brake Indicator Lamp Does Not Light When Parking Brake is Set to ON (Parking) Position2692
Brake Oil Pressure Caution Lamp Does Not Come On When Front Brake Accumulator Oil Pressure is Low2696
Brake Oil Pressure Caution Lamp Does Not Come On When Rear Brake Accumulator Oil Pressure is Low2697
Fuel Gauge Does Not Show Normally2698
Torque Converter Oil Temperature Gauge Does Not Increase, or Torque Converter Oil Temperature Caution Lamp Does Not Come On2700
Hydraulic Oil Temperature Gauge Does Not Rise or Hydraulic Oil Temperature Caution Lamp Does Not Come On2701
Seatbelt Caution Lamp Does Not Show Normally2703
Alarm Buzzer Does Not Operate2704
Alarm Buzzer Does Not Stop2706
Kickdown Does Not Operate When Kickdown Switch is ON Position2707
Hold Does Not Operate When Hold Switch is on Position2709
Parking Brake Does Not Operate Even If It is Applied, or the Brake Drags in Forward or Reverse Travel When Parking Brake is Released2711
Transmission Cut-off Mode is Not Selected or Not Released2715
Transmission Cut-off Setting Cannot be Released2717
Directional Selector (FNR) Switch Mode is Not Selected or Not Released2719
Engine Mode Selector Function Does Not Operate Normally When Engine Power Mode Selector Switch is Operated2721
Flow of Loader Pump Does Not Increase from the Minimum Rate2723
ECSS Function Cannot be Selected or Cannot be Released2724
ECSS Function Cannot be Selected or Cannot be Released (For AJSS Spec)2726
Horn Does Not Sound2728
Horn Does Not Sound (For AJSS Spec)2731
Horn Does Not Stop2734
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On2737
Headlamp, Clearance Lamp, and Tail Lamp Do Not Light (For AJSS Spec)2739
Clearance Lamp and Tail Lamp Do Not Come On or Go Out2741
Clearance Lamp and Tail Lamp Do Not Come On or Go Out (For AJSS Spec)2745
Clearance Lamp and Tail Lamp Do Not Come on or Go Out (For European Union)2749
High and Low Beams of Headlamp Do Not Come On or Go Out2753
High and Low Beams of Headlamp Do Not Come On or Go Out (For AJSS Spec)2757
High and Low Beams of Headlamp Do Not Come On or Go Out (EU Specification)2761
Low Beam of Headlamp Does Not Come On or Go Out2765
Low Beam of Headlamp Does Not Come On or Go Out (For AJSS Spec)2767
Low Beam of Headlamp Does Not Come On or Go Out (For European Union)2769
High Beam of Headlamp Does Not Come On or Go Out2771
High Beam of Headlamp Does Not Come On or Go Out (For AJSS Spec)2773
High Beam of Headlamp Does Not Come On or Go Out (For European Union)2775
Front Working Lamp Does Not Come On or Go Out2777
Front Working Lamp Does Not Come On or Go Out (EU Specifications)2782
Rear Working Lamp Does Not Come On or Go Out2787
Rear Working Lamp Does Not Come On or Go Out (For European Union)2791
Turn Signal Lamp and Hazard Lamp Do Not Come On or Go Out2796
All of Turn Signal Lamps and Hazard Lamps Do Not Come On or Go Out (For AJSS Spec)2799
Turn Signal Lamp Does Not Come On or Go Out2802
Turn Signal Lamps Do Not Come On or Go Out (For AJSS Spec)2805
Turn Signal Lamps Do Not Come On or Go Out (For European Union)2809
Hazard Lamp Does Not Come On or Go Out2812
Hazard Lamp Does Not Come On or Go Out (For European Union)2817
Brake Lamp Does Not Come On or Stays Lit2821
Backup Lamp Does Not Come On or Stays Lit2825
Backup Buzzer Does Not Sound or Continues to Sound2828
Front Wiper Does Not Operate2830
Front Wiper Does Not Operate (For AJSS Spec)2834
Rear Wiper Does Not Operate2838
Rear Wiper Does Not Operate (For AJSS Spec)2841
Fuel Feed Pump Does Not Operate or Stop Automatically2844
Fan Does Not Rotate in Reverse2847
Fan Remains Rotated in Reverse2848
Window Washer Does Not Operate2849
Window Washer Does Not Operate (For AJSS Spec)2852
KOMTRAX System Does Not Operate Correctly2855
Auto-Greasing Pump Display Shows [FCS]2856
Auto-Greasing Pump Display Shows [FLL]2858
Auto-Greasing System Does Not Operate or Stop2859
When Work Equipment Lock Switch is Operated, Work Equipment is Not Locked or Unlocked2861
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)2863
Information Shown in Troubleshooting Table (H-Mode)2863
Failure Mode and Cause Table2864
Machine Does Not Start2884
Lockup is Not Released2888
Torque Converter Lockup Clutch Does Not Engage2889
Travel Speed is Slow, Bucket Thrust Force is Weak, Gradability is Low, or Gear Speed Does Not Shift2890
Strong Shocks are Made When You Start Machine or Shift Gears2894
Time Lag is Large When You Start Machine or Shift Gears2897
Torque Converter Oil Temperature is High2900
Machine Does Not Turn (For Steering Wheel Spec)2903
Machine Does Not Turn (AJSS Specification)2905
Turning Response is Unsatisfactory (For Steering Wheel Specification)2907
Turning Response is Unsatisfactory (AJSS Specification)2909
Steering Wheel is Heavy to Operate2911
Machine Sways or Large Shocks are Made While Machine Turns (For Steering Wheel Specification)2912
Machine Sways or Large Shocks are Made While Machine Turns (AJSS Specification)2914
Turning Radius is Different on the Left and Right2916
Wheel Brakes Do Not Operate or are Weak2917
Wheel Brakes are Not Released or Drag2919
Parking Brake Does Not Operate or is Weak2920
Parking Brake is Not Released or Drags2921
Boom Does Not Rise2923
Boom Moves Slow or Lacks Lifting Force2925
Rising Boom Slows Down at Specified Height2927
Lift Cylinders Can Not Hold Bucket on Ground2928
Hydraulic Drift of Boom is Large2930
Boom Moves Up and Down During Operation2931
Bucket Does Not Tilt Back2932
Bucket Moves Slow or Lacks Tilt-Back Force2934
Bucket Slows Down During Tilt Back Operation2936
Bucket Cylinder Does Not Hold Bucket on Ground2937
Hydraulic Drift of Bucket is Large2939
Bucket Tilts Back and Forth When You Carry Load (Work Equipment Valve is in Hold)2940
Boom and Bucket Control Levers Do Not Move Smoothly and are Heavy to Move2941
Engine Speed Drops Largely or Engine Stops When You Operate Work Equipment2942
Large Shocks are Made When Work Equipment Starts to Move and Stops2943
When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves2946
ECSS Does Not Operate and Machine Pitches and Bounces2947
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)2948
Unusual Noise is Heard from Around Fan2950
Troubleshooting of Engine (S-Mode)2951
Information Shown in Troubleshooting Table (S-Mode)2951
Engine Does Not Crank When Starting Switch is Turned to Start Position2952
Engine Cranks but No Exhaust Smoke Comes Out2953
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)2954
Engine Startability is Unsatisfactory2955
Engine Does Not Pick Up Smoothly2957
Engine Stops During Operation2959
Engine Does Not Rotate Smoothly2961
Engine Lacks Output (or Lacks Power)2962
KDPF Becomes Clogged in a Short Time2964
Engine Oil Consumption is Excessive2966
Engine Oil Becomes Dirty Quickly2967
Fuel Consumption is Excessive2968
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)2969
Engine Oil Pressure Drops2970
Fuel Mixes Into Engine Oil2972
Water Mixes Into Engine Oil (Milky)2973
Coolant Temperature Increases Too High (Overheat)2974
Unusual Noise is Heard2975
Vibration is Excessive2976
Air Cannot be Bled from Fuel Circuit2977
Active Regeneration is Done Frequently2978
Active Regeneration Continues Long2980
White Smoke is Exhausted During Active Regeneration2981
DEF Consumption is Excessive2982
There is an Unusual Smell (Irritating Odor)2984
Foreign Materials Enter DEF (DEF Increases)2985
Troubleshooting for Auto-Greasing System2986
Outline of Failure Display2986
Troubleshooting for FCS2987
Troubleshooting for Auto-Greasing Pump2988
Replacement of Pump Element2991
Troubleshooting for Grease Supply System2992
Replace Auto-Greasing Controller2994
Assembly procedure when disassembled in troubleshooting2995
50 Disassembly and Assembly2997
Table of Contents2998
Precautions Before Work3003
Abbreviation List3004
Related Information on Disassembly and Assembly3010
How to Read This Manual3010
Coating Materials List3011
Special Tool List3016
Sketches of Special Tools3038
Engine and Cooling System3049
Remove and Install Supply Pump Assembly3049
How to Remove Supply Pump Assembly3049
How to Install Supply Pump Assembly3053
Remove and Install Injector Assembly3059
How to Remove Injector Assembly3059
How to Install Injector Assembly3064
Remove and Install Fuel Doser Assembly3070
How to Remove Fuel Doser Assembly3070
How to Install Fuel Doser Assembly3071
Remove and Install Cylinder Head Assembly3074
How to Remove Cylinder Head Assembly3074
How to Install Cylinder Head Assembly3086
Remove and Install EGR Valve Assembly3103
How to Remove EGR Valve Assembly3103
How to Install EGR Valve Assembly3103
Remove and Install EGR Cooler Assembly3105
How to Remove EGR Cooler Assembly3105
How to Install EGR Cooler Assembly3107
Remove and Install Starter Assembly3110
How to Remove Starting Motor Assembly3110
How to Install Starting Motor Assembly3111
Remove and Install Air Conditioner Compressor Belt3113
How to Remove Air Conditioner Compressor Belt3113
How to Install Air Conditioner Compressor Belt3115
Remove and Install Alternator Belt3118
How to Remove Alternator Belt3118
How to Install Alternator Belt3120
Remove and Install Automatic Tensioner3122
How to Remove Automatic Tensioner3122
How to Install Automatic Tensioner3122
Remove and Install Radiator Assembly3123
How to Remove Radiator Assembly3123
How to Install Radiator Assembly3128
Remove and Install Cooling Fan and Fan Motor Assembly3133
How to Remove Cooling Fan and Fan Motor Assembly3133
How to Install Cooling Fan and Fan Motor Assembly3137
Remove and Install Hydraulic Oil Cooler Assembly3140
How to Remove Hydraulic Oil Cooler Assembly3140
How to Install Hydraulic Oil Cooler Assembly3142
Remove and Install Aftercooler Assembly3144
How to Remove Aftercooler Assembly3144
How to Install Aftercooler Assembly3147
Remove and Install Power Train Oil Cooler Assembly3152
How to Remove Power Train Oil Cooler Assembly3152
How to Install Power Train Oil Cooler Assembly3157
Remove and Install Engine, Torque Converter, and Transmission Assembly3163
How to Remove Engine, Torque Converter, and Transmission Assembly3164
How to Install Engine, Torque Converter, and Transmission Assembly3181
Disconnect and Connect Engine, Torque Converter, and Transmission Assembly3198
How to Disconnect Engine, Torque Converter, and Transmission Assembly3198
How to Connect Engine, Torque Converter, and Transmission Assembly3199
Remove and Install Engine Front Oil Seal3200
How to Remove Engine Front Oil Seal3200
How to Install Engine Front Oil Seal3202
Remove and Install Engine Rear Oil Seal3205
How to Remove Engine Rear Oil Seal3205
How to Install Engine Rear Oil Seal3206
Remove and Install Engine Hood Assembly3212
How to Remove Engine Hood Assembly3212
How to Install Engine Hood Assembly3219
Remove and Install Fuel Tank Assembly3225
How to Remove Fuel Tank Assembly3225
How to Install Fuel Tank Assembly3230
Remove and Install DEF Tank Assembly3234
How to Remove DEF Tank Assembly3234
How to Install DEF Tank Assembly3238
Remove and Install DEF Tank Sensor Flange Assembly3242
How to Remove DEF Tank Sensor Flange Assembly3242
How to Install DEF Tank Sensor Flange Assembly3247
Remove and Install DEF Tank Sensor3251
How to Remove DEF Tank Sensor3251
How to Install DEF Tank Sensor3252
Remove and Install DEF Tank Strainer3259
How to Remove DEF Tank Strainer3259
How to Install DEF Tank Strainer3259
Remove and Install KDPF Assembly3261
How to Remove KDPF Assembly3262
How to Install KDPF Assembly3275
Disassemble and Assemble KDPF Assembly3290
How to Disassemble KDPF Assembly3290
How to Assemble KDPF Assembly3294
Remove and Install SCR Assembly3300
How to Remove SCR Assembly3301
How to Install SCR Assembly3311
Remove and Install KDPF and SCR Assembly3325
How to Remove KDPF and SCR Assembly3326
How to Install KDPF and SCR Assembly3337
Remove and Install Bellows Pipe Assembly3348
How to Remove Bellows Pipe Assembly3348
How to Install Bellows Pipe Assembly3353
Remove and Install KCCV Assembly3361
How to Remove KCCV Assembly3361
How to Install KCCV Assembly3361
Remove and Install VGT Assembly3363
How to Remove VGT Assembly3363
How to Install VGT Assembly3369
Remove and Install DEF Mixing Tube3375
How to Remove DEF Mixing Tube3375
How to Install DEF Mixing Tube3383
Remove and Install DEF Injector3392
How to Remove DEF Injector3392
How to Install DEF Injector3396
Remove and Install DEF Pump3400
How to Remove DEF Pump3400
How to Install DEF Pump3403
Remove and Install DEF Hose3406
How to Remove DEF Hose3406
How to Install DEF Hose3416
Remove and Install Air Cleaner Assembly3427
How to Remove Air Cleaner Assembly3427
How to Install Air Cleaner Assembly3428
Remove and Install Air Conditioner Compressor Assembly3430
How to Remove Air Conditioner Compressor Assembly3430
How to Install Air Conditioner Compressor Assembly3431
Remove and Install Air Conditioner Condenser Assembly3433
How to Remove Air Conditioner Condenser Assembly3433
How to Install Air Conditioner Condenser Assembly3434
Power Train3436
Disassemble and Assemble Torque Converter Assembly3436
How to Disassemble Torque Converter Assembly3436
How to Assemble Torque Converter Assembly3441
Disassemble and Assemble Transmission Assembly3448
How to Disassemble Transmission Assembly3450
How to Assemble Transmission Assembly3468
Disassemble and Assemble Transmission Clutch Pack Assembly3495
How to Disassemble Transmission Clutch Pack Assembly3496
How to Assemble Transmission Clutch Pack Assembly3512
Remove and Install Front Axle Assembly3532
How to Remove Front Axle Assembly3532
How to Install Front Axle Assembly3534
Remove and Install Rear Axle Assembly3536
How to Remove Rear Axle Assembly3536
How to Install Rear Axle Assembly3543
Disassemble and Assemble Axle Housing Assembly3551
How to Disassemble Axle Housing Assembly3552
How to Assemble Axle Housing Assembly3557
Disassemble and Assemble Axle Housing Assembly (Specifications of 55m3 Bucket)3565
How to Disassemble Axle Housing Assembly (Specifications of 55m3 Bucket)3566
How to Assemble Axle Housing Assembly (Specifications of 55m3 Bucket)3571
Disassemble and Assemble Differential Assembly3579
How to Disassemble Differential Assembly3580
How to Assemble Differential Assembly3589
Disassemble and Assemble Differential Assembly (Specifications of 55m3 Bucket)3608
How to Disassemble Differential Assembly (Specifications of 55m3 Bucket)3609
How to Assemble Differential Assembly (Specifications of 55m3 Bucket)3619
Steering System3637
Remove and Install Steering Valve Assembly3637
How to Remove Steering Valve Assembly3637
How to Install Steering Valve Assembly3640
Remove and Install Rotary Valve Assembly (For AJSS Spec)3643
How to Remove Rotary Valve Assembly3643
How to Install Rotary Valve Assembly3648
Brake System3657
Remove and Install Parking Brake Disc and Plate3657
How to Remove Parking Brake Disc and Plate3657
How to Install Parking Brake Disc and Plate3661
Undercarriage and Frame3665
Remove and Install Center Hinge Pin3665
How to Remove Center Hinge Pin3665
How to Install Center Hinge Pin3671
Remove and Install Counterweight Assembly3678
How to Remove Counterweight Assembly3678
How to Install Counterweight Assembly3681
Remove and Install Full-Length Fender Assembly3684
How to Remove Full-Length Fender Assembly3684
How to Install Full-Length Fender Assembly3685
Hydraulic System3686
Remove and Install Hydraulic Tank Assembly3686
How to Remove Hydraulic Tank Assembly3686
How to Install Hydraulic Tank Assembly3691
Remove and Install Work Equipment Pump and Cooling Fan Pump Assembly3697
How to Remove Work Equipment Pump and Cooling Fan Pump Assembly3697
How to Install Work Equipment Pump and Cooling Fan Pump Assembly3700
Remove and Install Steering Pump and Power Train Pump Assembly3702
How to Remove Steering Pump and Power Train Pump Assembly3702
How to Install Steering Pump and Power Train Pump Assembly3705
Remove and Install Control Valve Assembly3708
How to Remove Control Valve Assembly3708
How to Install Control Valve Assembly3712
Work Equipment3716
Remove and Install Work Equipment Assembly3716
How to Remove Work Equipment Assembly3716
How to Install Work Equipment Assembly3721
Disassemble and Assemble Hydraulic Cylinder Assembly3727
How to Disassemble Hydraulic Cylinder Assembly3728
How to Assemble Hydraulic Cylinder Assembly3731
CAB Related Parts3737
Remove and Install Operator Cab Assembly3737
How to Remove Operator Cab Assembly3737
How to Install Operator Cab Assembly3744
Remove and Install Operator Cab Glass (Adhered Glass)3751
How to Remove Operator Cab Glass (Adhered Glass)3751
How to Install Operator Cab Glass (Adhered Glass)3752
Remove and Install Air Conditioner Unit Assembly3761
How to Remove Air Conditioner Unit Assembly3761
How to Install Air Conditioner Unit Assembly3772
Remove and Install Operator Seat Assembly3782
How to Remove Operator Seat Assembly3782
How to Install Operator Seat Assembly3784
How to Remove and Install Seat Belt3786
How to Remove Seat Belt3786
How to Install Seatbelt3786
Electrical System3788
Remove and Install Engine Controller Assembly3788
How to Remove Engine Controller Assembly3788
How to Install Engine Controller Assembly3790
Remove and Install Work Equipment Controller Assembly3793
How to Remove Work Equipment Controller Assembly3793
How to Install Work Equipment Controller Assembly3794
Remove and Install Transmission Controller Assembly3797
How to Remove Transmission Controller Assembly3797
How to Install Transmission Controller Assembly3798
Remove and Install Monitor Controller Assembly3799
How to Remove Monitor Controller Assembly3799
How to Install Monitor Controller Assembly3801
Remove and Install Machine Monitor Assembly3804
How to Remove Machine Monitor Assembly3804
How to Install Machine Monitor Assembly3805
Remove and Install Mass Air Flow and Temperature Sensor3808
How to Remove Mass Air Flow and Temperature Sensor3808
How to Install Mass Air Flow and Temperature Sensor3809
Remove and Install KCCV Crankcase Pressure Sensor3810
How to Remove KCCV Crankcase Pressure Sensor3810
How to Install KCCV Crankcase Pressure Sensor3811
Remove and Install KDPF Temperature Sensor3813
How to Remove KDPF Temperature Sensor3813
How to Install KDPF Temperature Sensor3817
Remove and Install KDPF Differential Pressure Sensor3822
How to Remove KDPF Differential Pressure Sensor3822
How to Install KDPF Differential Pressure Sensor3826
Remove and Install SCR Temperature Sensor3830
How to Remove SCR Temperature Sensor3830
How to Install SCR Temperature Sensor3834
Remove and Install Ammonia Sensor3839
How to Remove Ammonia Sensor3839
How to Install Ammonia Sensor3842
Remove and Install SCR Outlet NOx Sensor3846
How to Remove SCR Outlet NOx Sensor3846
How to Install SCR Outlet NOx Sensor3850
Remove and Install KOMTRAX Terminal Assembly3854
How to Remove KOMTRAX Terminal Assembly3854
How to Install KOMTRAX Terminal Assembly3855
Remove and Install Gateway Function Controller Assembly3856
How to Remove Gateway Function Controller Assembly3856
How to Install Gateway Function Controller Assembly3857
Remove and Install Communication Terminal3858
How to Remove Communication Terminal3858
How to Install Communication Terminal3863
60 Maintenance Standard3869
Table of Contents3870
Abbreviation List3871
Engine and Cooling System3877
Maintenance Standard for Engine Mount3877
Maintenance Standard for Brake and Cooling Fan Pump3878
Maintenance Standard for Servo Valve of Brake and Cooling Fan Pump3880
Maintenance Standard for Cooling Fan Motor3881
Power Train3883
Maintenance Standard for Drive Shaft3883
Maintenance Standard for Torque Converter3884
Maintenance Standard for Lockup Clutch ECMV3886
Maintenance Standard for Transmission3887
Maintenance Standard for F, 1st Clutch3893
Maintenance Standard for R, 2nd Clutch3895
Maintenance Standard for 3rd, 4th Clutch3897
Maintenance Standard for Transmission Control Valve3899
Maintenance Standard for Forward and Reverse Clutch ECMV and 1st, 2nd Clutch ECMV3901
Maintenance Standard for 3rd, 4th Clutch ECMV3902
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve3903
Maintenance Standard for Front Axle3904
Maintenance Standard for Rear Axle3906
Maintenance Standard for Front Conventional Differential3908
Maintenance Standard for Rear Conventional Differential3914
Maintenance Standard for Front Limited Slip Differential3920
Maintenance Standard for Rear Limited Slip Differential3924
Maintenance Standard for Final Drive3928
Steering System3934
Maintenance Standard for Steering Column3934
Maintenance Standard for Steering Pump3935
Maintenance Standard for Servo Valve of Steering Pump3938
Maintenance Standard for Steering Valve3939
Maintenance Standard for Steering Cylinder3941
Maintenance Standard for Secondary Steering Pump3943
Brake System3944
Maintenance Standard for Charge Valve3944
Maintenance Standard for Brake Circuit Accumulator3946
Maintenance Standard for Slack Adjuster3947
Maintenance Standard for Front Brake3948
Maintenance Standard for Rear Brake3951
Maintenance Standard for Parking Brake3954
Maintenance Standard for Parking Brake Solenoid Valve3956
Maintenance Standard for Flow Priority Valve3957
Maintenance Standard for Brake Cooling Pump3958
Maintenance Standard for Brake Cooling Strainer3959
Undercarriage and Frame3960
Maintenance Standard for Frame, Axle Mount and Center Hinge Pin3960
Hydraulic System3971
Maintenance Standard for Hydraulic Tank3971
Maintenance Standard for Work Equipment Pump3973
Maintenance Standard for Power Train Charge Pump and Power Train Lubrication Pump3975
Maintenance Standard for Control Valve3976
Maintenance Standard for Work Equipment Lock Solenoid Valve3985
Work Equipment3986
Maintenance Standard for Work Equipment Linkage3986
Maintenance Standard for Bucket3990
Maintenance Standard for Lift Cylinder3991
Maintenance Standard for Bucket Cylinder3992
80 Appendix3993
Table of Contents3994
Precautions Before Work3996
Abbreviation List3997
Air Conditioner System4003
Precautions for Refrigerant4003
Air Conditioner Component4004
Specifications of Air Conditioner4006
Structure and Function of Refrigeration Cycle4007
Outline of Refrigeration Cycle4008
Component Parts of Air Conditioner System4010
Air Conditioner Unit4010
Configuration Diagram of Air Conditioner Unit4010
Function of Air Conditioner Unit4011
Component Parts of Air Conditioner Unit4012
Function of Evaporator as Air Conditioner Unit Component4012
Function of Inside Air Temperature Sensor as Air Conditioner Unit Component4012
Function of Blower Amplifier as Air Conditioner Unit Component4013
Function of Blower OFF Relay as Air Conditioner Unit Component4013
Function of Compressor Clutch Relay as Air Conditioner Unit Component4013
Function of Heater Core as Air Conditioner Unit Component4013
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component4013
Function of Servo Motor as Air Conditioner Unit Component4013
Function of Expansion Valve as Air Conditioner Unit Component4014
Function of Dual Pressure Switch4014
Air Conditioner Controller4015
Structure of Air Conditioner Controller4015
Compressor4016
Structure of Compressor4016
Specifications of Compressor4016
Function of Compressor4016
Condenser4017
Structure of Condenser4017
Specifications of Condenser4017
Function of Condenser4017
Receiver Drier4018
Structure of Receiver Dryer4018
Specifications of Receiver Dryer4018
Function of Receiver Dryer4018
Air Conditioner Related Sensors4019
Function of Sunlight Sensor4019
Function of Outside Air Temperature Sensor4019
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner4020
Circuit Diagram and Configuration of Connector Pins of Air Conditioner4022
System Diagram of Air Conditioner4025
Input and Output Signals of Air Conditioner Controller4026
Function of Air Conditioner Controller4027
Locations of Air Conditioner Parts and Layout of Connectors4028
Examine Air Conditioner with Self-Diagnosis Function4034
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor4035
Examine Temperature Control Function4036
How to Examine Temperature Control Function4036
Examine Vent (Mode) Changeover4038
How to Examine Vent (Mode) Changeover4038
Examine Fresh/Recirc Air Changeover4040
How to Examine Fresh/Recirc Air Changeover4040
Examine Evaporator Temperature Sensor4042
Examine Relay4044
How to Examine Relay4044
Air Conditioner Troubleshooting Chart 14046
Air Conditioner Troubleshooting Chart 24047
Information Shown in Troubleshooting Table4050
Failure Code [879AKA]4051
Failure Code [879AKB]4053
Failure Code [879BKA]4055
Failure Code [879BKB]4057
Failure Code [879CKA]4059
Failure Code [879CKB]4061
Failure Code [879DKZ]4063
Failure Code [879EMC]4065
Failure Code [879FMC]4068
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)4071
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)4074
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)4077
Troubleshooting for Fresh/Recirc Air Changeover4081
Troubleshooting by Gauge Pressure4083
Connect Service Tool4086
How to Connect Service Tool4087
Precautions for Disconnection and Connection of Air Conditioner Piping4088
Handle Compressor Oil4090
90 Circuit Diagrams4093
Table of Contents4094
Abbreviation List4096
Hydraulic Circuit Diagram4102
Symbols Used in Hydraulic Circuit Diagram4102
Hydraulic Circuit Diagram (For AJSS Spec)4107
Hydraulic Circuit Diagram (For Steering Wheel Spec)4109
Power Train Hydraulic Circuit Diagram4111
Hydraulic Oil Pressure of Brake Cooling System4113
Hydraulic Auto-Greasing Diagram4117
Electrical Circuit Diagram4119
Symbols Used in Electric Circuit Diagram4119
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (1/6)4123
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (2/6)4125
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (3/6)4127
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (4/6)4129
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (5/6)4131
Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (6/6)4133
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (1/6)4135
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (2/6)4137
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (3/6)4139
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (4/6)4141
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (5/6)4143
Electrical Circuit Diagram of Machine (Machine with gateway function controller) (6/6)4145
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (1/9)4147
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (2/9)4149
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (3/9)4151
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (4/9)4153
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (5/9)4155
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (6/9)4157
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (7/9)4159
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (8/9)4161
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with KOMTRAX Terminal) (9/9)4163
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (1/10)4165
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (2/10)4167
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (3/10)4169
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (4/10)4171
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (5/10)4173
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (6/10)4175
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (7/10)4177
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (8/10)4179
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (9/10)4181
Electrical Circuit Diagram of Floor (For AJSS Spec) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (10/10)4183
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (1/9)4185
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (2/9)4187
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (3/9)4189
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (4/9)4191
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (5/9)4193
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (6/9)4195
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (7/9)4197
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (8/9)4199
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with KOMTRAX Terminal) (9/9)4201
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (1/10)4203
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (2/10)4205
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (3/10)4207
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (4/10)4209
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (5/10)4211
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (6/10)4213
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (7/10)4215
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (8/10)4217
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (9/10)4219
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 100439 to 101011) (10/10)4221
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (1/10)4223
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (2/10)4225
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (3/10)4227
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (4/10)4229
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (5/10)4231
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (6/10)4233
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (7/10)4235
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (8/10)4237
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (9/10)4239
Electrical Circuit Diagram of Floor (For European Union and Japan) (Machine with Gateway Function Controller) (Applicable Machine: 101012 and Up) (10/10)4241
Electrical Circuit Diagram (Brake Cooling System)4243
Index4245
S.M 29/12/24
