Komatsu WHEEL LOADER WA800-8 WA900-8 Shop Manual SEN06799-14 PDF
$41.95
Komatsu WHEEL LOADER WA800-8 WA900-8 Shop Manual SEN06799-14 – PDF DOWNLOAD
SERIAL NUMBERS WA800-80001
WA900-90001 and up
Description
Komatsu WHEEL LOADER WA800-8 WA900-8 Shop Manual SEN06799-14 – PDF DOWNLOAD
FILE DETAILS:
Komatsu WHEEL LOADER WA800-8 WA900-8 Shop Manual SEN06799-14 – PDF DOWNLOAD
Language : English
Pages :6380
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WHEEL LOADER WA800-8 WA900-8 Shop Manual SEN06799-14 – PDF DOWNLOAD
SERIAL NUMBERS WA800-80001
WA900-90001 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 WA800-8 WA900-8 Shop Manual SEN06799-14 – PDF DOWNLOAD
SERIAL NUMBERS WA800-80001
WA900-90001 and up
Cover 1
00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 27
How to Read the Shop Manual 27
Safety Notice for Operation 29
Precautions to Prevent Fire 37
Procedures If Fire Occurs 39
Precautions When You Dispose of Waste Materials 40
Engine Technology to Conform Exhaust Gas Emission 41
Precautions When You Handle Hydraulic Equipment 42
Precautions When You Disconnect and Connect Pipings 45
Precautions When You Handle Electrical Equipment 52
Precautions When You Handle Fuel System Equipment 54
Precautions When You Handle Intake System Equipment 55
Practical Use of KOMTRAX 56
Disconnect and Connect Push-Pull Type Coupler 57
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 57
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 58
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 59
Precautions for Disconnection and Connection of Connectors 61
How to Disconnect and Connect Deutsch Connector 65
How to Disconnect and Connect Slide Lock Type Connector 66
How to Disconnect and Connect Connector with Lock to Pull 68
How to Disconnect and Connect Connector with Lock to Push 69
How to Disconnect and Connect Connector with Housing to Rotate 71
Standard Tightening Torque Table 72
Conversion Table 79
Abbreviation List 84
01 Specifications 87
Table of Contents 88
Specifications 89
Specification Drawing 89
Specification Drawing WA800-8 89
Specification Drawing WA900-8 91
Specifications 93
Specifications WA800-8 93
Specifications WA900-8 98
Weight Table 103
Weight Table WA800-8 103
Weight Table WA900-8 105
Fuel, Coolant, Lubricant 107
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 107
10 Structure and Function 109
Table of Contents 110
Boot-up System 116
Layout Drawing of Boot-up System 116
Pre-lubrication System 118
Pre-lubrication System Diagram 118
Function of Pre-lubrication System 118
Operation of Pre-lubrication System 120
System Operating Lamp System 122
System Diagram of System Operating Lamp System 122
Function of Operation Lamp System 122
Operation of System Operating Lamp System 122
Battery Disconnect Switch 123
Function of Battery Disconnect Switch 123
Operation of Battery Disconnect Switch 123
Starting Motor Disconnect Switch 124
Function of Starting Motor Disconnect Switch 124
Preheating System 125
System Diagram of Preheating System 125
Function of Automatic Preheating System 125
Operation of Automatic Preheating System 126
Function of Manual Preheating System 126
Operation of Manual Preheating System 126
Engine Shutdown Secondary Switch 127
Function of Engine Shutdown Secondary Switch 127
Operation of Engine Shutdown Secondary Switch 127
Emergency Engine Stop Switch 128
Function of Emergency Engine Stop Switch 128
Operation of Emergency Engine Stop Switch 128
External Power Supply Engine Preheater 129
Function of External Power Supply Engine Preheater 129
Engine System 130
Layout Drawing of Engine System 130
Engine Control System 132
System Diagram of Engine Control 132
Operation of Engine Control System 133
Engine Output Torque Control Function 134
Engine Automatic Warm-up Function 134
Engine Power Mode Selector System 135
Engine Power Mode Selector System Diagram 135
Function of Engine Power Mode Selector System 135
Operation of Engine Power Mode Selector System 135
Automatic Idle Stop System 136
Function of Automatic Idle Stop System 136
RPM Set 137
Function of RPM Set 137
Component Parts of Engine System 139
Damper 139
VGT 141
EGR System 145
EGR Valve 149
EGR Cooler 151
KCCV System 152
KCCV 155
KDPF 157
Cooling System 161
Layout Drawing of Cooling System 161
Specifications of Cooling System 163
Cooling Fan Control System 164
System Diagram of Cooling Fan Control System 164
Function of Cooling Fan Control System 165
Component Parts of Cooling System 168
Cooling Fan Pump 168
Cooling Pump 176
Cooling Fan Motor 177
Control System 183
Layout Drawing of Control System 183
Machine Monitor System 185
System Diagram of Machine Monitor System 185
Function of Machine Monitor System 186
Rearview Monitor System 187
System Diagram of Rearview Monitor System 187
Function of Rearview Monitor System 187
KOMTRAX Plus System 188
System Diagram of KOMTRAX Plus System 188
Function of KOMTRAX Plus System 188
Load Meter System 190
System Diagram of Load Meter 190
Function of Load Meter System 190
Machine Lock-out System 196
Layout Drawing of Machine Lock-out System 196
Function of Machine Lock-out System 196
Operation of Machine Lock-out System 196
Component Parts of Control System 198
Machine Monitor 198
Switch Panel 216
Rearview Monitor 217
Rearview Camera 219
KOMTRAX Terminal 220
KOMTRAX Plus Controller 222
Wireless LAN Unit 227
Transmission Controller 228
Work Equipment Controller 232
Monitor Controller 236
CAN Terminating Resistor 241
Engine Controller 242
Accelerator Pedal 255
Fuel Feed Pump 258
Fuel Feed Pump Switch 259
Hydraulic System 260
Layout Drawing of Hydraulic System 260
CLSS 261
Structure of CLSS 261
Function of CLSS 262
Work Equipment Pump Control System 264
Swash Plate Control Function of Work Equipment Pump 264
Pickup Assistance Control Function of Work Equipment Pump When Engine Speed is Low 264
Steering Pump Control System 266
Swash Plate Control Function of Steering Pump 266
Pickup Assistance Control Function of Steering Pump When Engine Speed is Low 266
Component Parts of Hydraulic System 267
Hydraulic Tank 267
Work Equipment Pump 271
Steering Pump 290
Pilot Brake Charge Pump 306
Pump Assembly (to Lubricate Transmission and Torque Converter) 307
Accumulator Charge Valve 308
Control Valve 313
Power Train System 348
Layout Drawing of Power Train System 348
Operation of Power Train System 351
Transmission Control System 352
Transmission Control System Diagram 352
Transmission Gear Shift Control System 354
Electric Modulation Function System Diagram 354
Electric Modulation Function 355
Gear Shift Display Function 355
Automatic Gear Shift Function 355
Shift Hold Function 356
Kickdown Function 356
Automatic Kickdown Function 357
Hunting Prevention Function 357
Transmission Initial Learning and ECMV Current Adjustment Function 357
Shift Point Changing Function 357
3rd Gear Speed Limitation Function 358
Transmission Protection Function 359
Protection Function When Travel Direction is Changed 359
Shift Down Protection Function 359
Engine Overrun Prevention Function 360
Neutralizer Function 360
Modulation Clutch Control Function 360
Tire Slip Control System 363
Tire Slip Control System Diagram 363
Function of Tire Slip Control System 363
Operation of Tire Slip Control System 363
Component Parts of Power Train System 365
Drive Shaft 365
Center Support 367
Torque Flow Assembly 368
Torque Converter 369
Valve Assembly (For Main Relief and Torque Converter Relief) 377
Torque Converter Regulator Valve 380
Transmission 382
Transmission Control Valve 400
Modulation Clutch ECMV 403
F, R, 1st, 2nd, 3rd Clutch ECMV 406
Transmission Lubrication Relief Valve 411
Axle 412
Differential 415
Final Drive 418
AJSS Knob 420
Shift Hold Switch 421
Kickdown Switch 422
Work Equipment System 423
Layout Drawing of Work Equipment System 423
Work Equipment System Diagram 425
Work Equipment Control System 427
Work Equipment Speed Pattern Control Function by Work Equipment Lever Stroke 427
Work Equipment Lever Detent Position and Work Equipment Startup Current Control Function 428
Work Equipment Lever Operating Function System Diagram 429
Work Equipment Lever Operation Function 429
Bucket Priority Control Function 430
Boom Stop Modulation Function 430
Work Equipment Shock Reduction Function 431
Tilt Shock Reduction Function 431
Dump Shock Reduction Function 432
Work Equipment Neutral Lock System 434
Work Equipment Neutral Lock System Diagram 434
Function of Work Equipment Neutral Lock System 434
Remote Positioner System 436
Remote Bucket Positioner System Diagram 436
Function of Remote Bucket Positioner System 436
Remote Boom Positioner System Diagram 437
Function of Remote Boom Positioner System 437
Bucket Positioner and Boom Positioner 441
Structure of Bucket Positioner and Boom Positioner 441
Auto-Digging System 442
Auto-Digging System Diagram 442
Function of Auto-Digging System 442
Semi-Auto Approach System 444
Semi-Auto Approach System Diagram 444
Function of Semi-Auto Approach System 444
Semi-Auto Dump System 445
Semi-Auto Dump System Diagram 445
Function of Semi-Auto Dump System 445
ECSS 447
ECSS Diagram 447
Function of ECSS 447
Operation of ECSS 447
Wall Digging Prevention Control System 449
Wall Digging Prevention Control System Diagram 449
Function of Wall Digging Prevention Control System 449
Component Parts of Work Equipment System 451
Solenoid Valve (Work Equipment Lock) 451
Pilot Circuit Accumulator 452
ECSS Circuit Accumulator 453
Work Equipment Electric Lever 454
Steering System 457
Layout Drawing of Steering System 457
Secondary Steering System 458
Secondary Steering System Diagram 458
Function of Secondary Steering System 458
AJSS 459
Layout Drawing of AJSS 459
AJSS System Diagram 460
Function of AJSS 461
Neutralizer Function of AJSS 462
AJSS Neutral Interlock Function 462
AJSS Speed Sensing Steering Function 463
AJSS Turn Signal Pilot Lamp Control Function 465
Steering Lock System 466
Steering Lock System Diagram 466
Function of Steering Lock System 466
Component Parts of Steering System 467
AJSS EPC Valve 467
Solenoid Valve (For Steering Lock) 468
Steering Lock Valve 469
Rotary Valve 470
Steering Valve 474
Diverter Valve 488
Secondary Steering Relief Valve 491
Secondary Steering Pump 493
Lubrication for Hinge Pin and Steering 494
Brake System 495
Layout Drawing of Brake System 495
Parking Brake Control System 498
System Diagram of Parking Brake Control System 498
Operation of Parking Brake Control System 498
Component Parts of Brake System 500
Solenoid Valve (Parking Brake) 500
Parking Brake Emergency Release Valve 502
Brake Circuit Accumulator 503
Brake Valve 504
Slack Adjuster 510
Brake 513
Parking Brake 515
Parking Brake Circuit Check Valve 518
Pump Assembly (For Brake Cooling) 519
Auto-Greasing System 520
Layout Drawing of Auto-Greasing System 520
Auto-Greasing System Diagram 523
Specifications of Auto-Greasing System 524
Function of Auto-Greasing System 525
Auto-Greasing System 526
Auto-Greasing Pump 526
Auto-Greasing Injector 528
Lifting System 531
Power Ladder System 531
Layout Drawing of Power Ladder System 531
Power Ladder System Diagram 532
Function of Power Ladder System 533
Operation of Power Ladder System 533
Power Ladder System 535
Power Ladder Pump 535
Power Ladder Relief Valve 537
Solenoid Valve (Power Ladder Shock Reduction) 538
Solenoid Valve (Power Ladder Raise and Lower Switch) 539
Undercarriage and Frame 540
Frame, Axle Mount and Hinge Pin 540
Structure of Frame, Axle Mount and Hinge Pin 540
Function of Frame, Axle Mount and Hinge Pin 542
Structure of Lubrication System for Undercarriage 543
Service Center 544
Service Center 544
Service Center System Diagram 545
Function of Service Center 545
Grease Refill Automatic Stop System 546
Tires 548
Structure of Radial Tire 548
Function of Radial Tire 548
Work Equipment 549
Structure of Work Equipment 549
Structure of Bucket 550
Structure of Lubrication System for Work Equipment 551
CAB Related Parts 553
ROPS 553
Structure of ROPS 553
Function of ROPS 553
CAB 554
Structure of CAB 554
CAB Mount 555
Structure of CAB Mount 555
Function of CAB Mount 555
20 Standard Value Table 557
Table of Contents 558
Standard Value Table for Engine 559
Standard Value Table for Engine: WA800-8 559
Standard Value Table for Engine: WA900-8 564
Standard Value Table for Machine 569
Standard Value Table for Machine: WA800-8 569
Standard Value Table for Machine: WA900-8 584
Machine Posture and Procedures to Measure Performance 598
30 Testing and Adjusting 601
Table of Contents 602
Precautions Before Work 606
Related Information on Testing and Adjusting 607
Tools for Testing and Adjusting 607
Sketch of Tools for Testing and Adjusting 617
Engine and Cooling System 618
Examine Engine Speed 618
How to Examine Engine Speed 618
Examine Boost Pressure 622
How to Examine Boost Pressure on Machine Monitor 622
How to Examine Boost Pressure by Testing Tool 623
Examine Exhaust Gas Temperature 626
How to Examine Exhaust Gas Temperature 626
Examine Exhaust Gas Color 628
How to Examine Exhaust Gas Color with the Handy Smoke Checker 628
How to Examine Exhaust Gas Color with Smoke Meter 631
Examine Mass Air Flow and Temperature Sensor 636
How to Examine Mass Air Flow and Temperature Sensor 636
Examine and Adjust Valve Clearance 641
How to Examine Valve Clearance 641
How to Adjust Valve Clearance 643
Examine Compression Pressure 644
How to Examine Compression Pressure 644
Examine Blowby Pressure 648
How to Examine Blowby Pressure 648
Examine Engine Oil Pressure 653
How to Examine Engine Oil Pressure on Machine Monitor 653
How to Examine Engine Oil Pressure by Testing Tool 654
Examine EGR Valve and VGT Oil Pressure 656
How to Examine EGR Valve and VGT Oil Pressure 656
Examine Fuel Pressure 658
How to Examine Fuel Pressure 658
Examine Fuel Return Rate and Leakage 660
How to Examine Fuel Return Rate and Leakage 661
Bleed Air from Fuel System 668
How to Bleed Air from Fuel System 668
Examine Fuel Circuit for Leakage 670
How to Examine Fuel System for Leakage 670
Examine Low Pressure Circuit Devices 671
How to Examine Low Pressure Circuit Devices 671
Handle Cylinder Cut-out Mode Operation 679
Handle No-Injection Cranking Operation 680
Examine KDPF and Muffler Stack for Looseness and Damage 681
How to Examine KDPF and Muffler Stack for Looseness and Damage 681
Examine Installation of Cylinder Head Cover and Manifolds 682
How to Examine Installed Condition of Cylinder Head covers and Manifolds 682
Examine Engine Piping for Damage and Looseness 683
How to Examine Engine Piping for Damage and Looseness 683
Clean Fuel Doser 684
How to Clean Fuel Doser 684
Write Injector Compensation Value to Engine Controller 687
How to Write Injector Compensation Value 687
Write Correction for Ash in Soot Accumulation to Engine Controller 694
How to Write Correction for Ash in Soot Accumulation to Engine Controller 694
Examine and Adjust Alternator Belt 695
How to Examine Alternator Belt 695
How to Adjust Alternator Belt Tension 696
Examine and Adjust Air Conditioner Compressor Belt 697
How to Examine Air Conditioner Compressor Belt 697
How to Adjust Air Conditioner Compressor Belt Tension 698
Bleed Air from Engine Coolant Circuit 699
How to Bleed Air from Engine Coolant Circuit 699
Power Train 701
Examine and Adjust Power Train Oil Pressure 701
How to Examine Power Train Oil Pressure 703
How to Adjust Power Train Oil Pressure 718
Examine Modulation Clutch Output Speed Sensor 720
How to Examine Modulation Clutch Output Speed Sensor 720
Examine Transmission Output Speed Sensor 721
How to Examine Transmission Output Speed Sensor 721
Adjust Wheel Speed Sensor 723
How to Adjust Wheel Speed Sensor 723
Flush Torque Converter and Transmission Hydraulic Circuit 724
How to Flush Torque Converter and Transmission Hydraulic Circuit 724
Move Disabled Machine Due to Transmission Valve Failure 727
How to Move Disabled Machine Due to Transmission Valve Failure 727
Examine Drive Shaft for Looseness, Backlash, and Damage 730
How to Examine Drive Shaft for Looseness, Backlash, and Damage 730
Steering System 731
Examine and Adjust Steering Circuit Oil Pressure 731
How to Examine Steering Circuit Oil Pressure 731
How to Adjust Steering Circuit Oil Pressure 734
Brake System 736
Release Remained Pressure in Brake Accumulator Circuit 736
How to Release Remained Pressure in Brake Accumulator Circuit 736
Examine Wheel Brake Oil Pressure 737
How to Examine Wheel Brake Oil Pressure 737
Examine and Adjust Brake Accumulator Charge Pressure 739
How to Examine Brake Accumulator Charge Pressure 739
How to Adjust Brake Accumulator Charge Pressure 741
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas 743
How to Examine Accumulator Nitrogen Gas Pressure for Brake 743
How to Charge Accumulator Nitrogen Gas for Brake 747
How to Release Nitrogen Gas When You Discard Accumulator 752
Examine Brake Performance 753
How to Examine Brake Performance 753
Examine Brake Pedal 754
How to Examine Brake Pedal 754
Adjust Right Brake Pedal Switch 756
How to Adjust Right Brake Pedal Switch 756
Bleed Air from Brake Circuit 758
How to Bleed Air from Brake Circuit 758
Examine Wear of Wheel Brake Disc 760
How to Examine Wear of Wheel Brake Disc 760
Examine Parking Brake Oil Pressure 762
How to Examine Parking Brake Oil Pressure 762
Examine Parking Brake Performance 764
How to Examine Parking Brake Performance 764
Release Parking Brake Manually 765
How to Release Parking Brake Manually 765
Examine Wear Volume of Parking Brake Disc 767
How to Examine Wear Quantity of Parking Brake Disc 767
Hydraulic System 769
Release Remained Pressure from Work Equipment Circuit 769
How to Release Remained Pressure from Work Equipment Circuit 769
Examine and Adjust Work Equipment Oil Pressure 771
How to Examine Work Equipment Oil Pressure 771
How to Adjust Work Equipment Oil Pressure 776
Examine and Adjust Work Equipment EPC Oil Pressure 778
How to Examine Work Equipment EPC Oil Pressure 778
How to Adjust Work Equipment EPC Oil Pressure 780
Bleed Air from Hydraulic System 781
How to Bleed Air from Hydraulic System 781
Examine Cooling Fan Speed 787
How to Examine Cooling Fan Speed 787
Examine Cooling Fan Circuit Oil Pressure 788
How to Examine Cooling Fan Circuit Oil Pressure 788
How to Examine Cooling Fan Reverse Solenoid Outlet Pressure 789
Bleed Air from Cooling Fan Circuit 792
How to Bleed Air from Cooling Pump 792
How to Bleed Air from Fan Motor Circuit 793
Examine ECSS Accumulator Charge Pressure 794
How to Examine ECSS Accumulator Charge Pressure 794
Examine ECSS Accumulator Nitrogen Gas Pressure and Charge Accumulator with Nitrogen Gas 796
How to Examine ECSS Accumulator Nitrogen Gas Pressure 796
How to Charge ECSS Accumulator with Nitrogen Gas 799
Work Equipment 804
Examine and Adjust Bucket Potentiometer Lever 804
How to Examine Bucket Potentiometer Lever 804
How to Adjust Bucket Potentiometer Lever 804
Examine and Adjust Boom Potentiometer Lever 806
How to Examine Boom Potentiometer Lever 806
How to Adjust Boom Potentiometer Lever 806
Examine Hydraulic Drift of Work Equipment 807
How to Examine Hydraulic Drift of Work Equipment 807
Examine Work Equipment Speed 809
How to Examine Work Equipment Speed 809
Device to Get on or Off Machine 810
Adjust Deceleration of Power Ladder 810
How to Adjust Deceleration of Power Ladder 811
CAB Related Parts 813
Examine Work Equipment Control Lever 813
How to Examine Work Equipment Control Lever 813
Examine AJSS Lever 815
How to Examine Operating Time of AJSS Lever 815
How to Examine Operating Force of AJSS Lever 816
How to Examine Operating Force of Directional Switch 817
How to Examine Operating Force of Gear Speed Switch 817
Examine and Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor 818
How to Examine AJSS Lever Angle Sensor and AJSS Frame Angle Sensor 818
How to Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor 818
Examine and Adjust Steering Stopper Bolt 820
How to Examine Steering Stopper Bolt 820
How to Adjust Steering Stopper Bolt 820
Adjust Play of Operator Seat 821
How to Adjust Play of Operator Seat 821
Adjust Door Lock Link 822
How to Adjust Door Lock Link 822
Electrical System 825
Set and Adjust Each Equipment 825
Set and Operate Machine Monitor 830
Operator Mode 834
Function to Show Operator Identification Input Screen 834
Examine Function by LCD (Liquid Crystal Display) 835
Examine Function of Service Meter and Odometer 836
How to Set Usage Limitation and Change Maintenance Password 836
Service Mode 840
How to Operate Service Mode 840
How to See Pre-defined Monitoring Information 842
How to Examine Monitoring Information 848
Abnormality Record Menu 863
How to See Maintenance Record 867
Maintenance Mode Setting 869
How to Set Phone Number Entry 875
Default Setting Menu 876
Testing Menu 896
Adjustment Menu 909
No-Injection Cranking Operation 946
KOMTRAX Settings Menu 949
How to Show Service Message 951
How to Operate Snap Shot 952
How to Start Up KOMTRAX Terminal 955
How to Stop Use of KOMTRAX Terminal 959
Default Setting of KOMTRAX Plus Controller 961
Default Setting of KOMTRAX Plus Controller 961
Default Setting of Wireless LAN Modem 964
Default Setting of Wireless LAN Modem 964
How to Examine Wireless LAN Modem Communication 965
Download Data from KOMTRAX Plus Controller 967
How to Download Data from KOMTRAX Plus Controller 967
How to Download Data from Service Connector 967
How to Download Data from Wireless LAN 968
Adjust After Replacement of KOMTRAX Plus Controller 970
How to Adjust After Replacement of KOMTRAX Plus Controller 970
Adjust After Replacement of Wireless LAN Modem 973
How to Adjust After Replacement of Wireless LAN Modem 973
Adjust Rearview Camera Angle 976
How to Adjust Rearview Camera Angle 976
Set Region of Bluetooth(R) Compatible Radio 977
How to Set Region of Bluetooth(R) Compatible Radio 977
Handle Voltage Circuit of Engine Controller 979
Handle Battery Disconnect Switch 980
Examine Diodes 981
How to Examine Diodes by Digital Tester 981
How to Examine Diodes by Analog Tester 981
Pm Clinic 982
Pm Clinic Service 982
Pm Clinic Check Sheet: WA800-8 985
Pm Clinic Check Sheet: WA900-8 997
Perform Quick Pm1009
How to Perform Quick Pm1009
40 Troubleshooting1013
Table of Contents1014
Precautions Before Work1030
Related Information for Troubleshooting1031
General Troubleshooting Points1031
Troubleshooting Points for Aftertreatment System1032
Sequence of Events in Troubleshooting1038
Checks Before Troubleshooting1040
Inspection Procedure Before Troubleshooting1042
Walk-Around Check1042
Test in Accordance with Testing Procedure1044
Examine Fuel Level and Type1044
Examine for Impure Ingredient in Fuel1044
Replace Fuel Prefilter Cartridge1045
Replace Fuel Main Filter Cartridge1046
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type1048
Examine Coolant Level (Reservoir Tank)1049
Examine, Clean and Replace Air Cleaner1050
Examine Hydraulic Oil Level1055
Examine Hydraulic Oil Filter or Hydraulic Oil Strainer1056
Examine Oil Level in Transmission Case1057
Examine Oil Level in Axle Case1059
Bleed Air from Fuel System1061
Bleed Air from Hydraulic System1061
How to Examine Electric Equipment1061
Preparation for Troubleshooting of Electrical System1068
How to Connect Adapter for Troubleshooting Work Equipment Controller1068
How to Connect Adapter for Troubleshooting Engine Controller1069
How to Connect Adapter to Troubleshoot Transmission Controller1070
How to Connect Adapter to Troubleshoot Monitor Controller1071
How to Connect Adapter to Troubleshoot KOMTRAX Terminal1074
How to Connect Adapter to Troubleshoot KOMTRAX Plus Controller1074
How to Connect Adapter to Troubleshoot KomVision Controller1075
How to Connect Connectors for Engine Related Parts1075
How to Disconnect KomVision Radar Connector1079
Procedure for Troubleshooting1081
Symptom and Troubleshooting Numbers1084
Information Shown in Troubleshooting1096
Connectors List1099
Connector Layout1123
Connector Contact Connection Table1139
T-Branch Box and T-Branch Adapter Table1186
Fuse Location Table1192
Precautions When You Clean and Replace KDPF (KCSF and KDOC)1196
Prepare Troubleshoot Machine Monitor1200
Procedure to Make Harness Checker on Machine Monitor LCD Unit1202
Prepare of Short Circuit Electrical Connector (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135])1207
Failure Code Table1209
Troubleshooting by Failure Code (Display of Code)1239
Failure Code [1500L0]1239
Failure Code [15B0NX]1241
Failure Code [15SAL1]1244
Failure Code [15SALH]1247
Failure Code [15SBL1]1250
Failure Code [15SBLH]1253
Failure Code [15SEL1]1256
Failure Code [15SELH]1259
Failure Code [15SFL1]1262
Failure Code [15SFLH]1265
Failure Code [15SGL1]1268
Failure Code [15SGLH]1271
Failure Code [15W0NT]1274
Failure Code [2F00MA]1276
Failure Code [2F00MB]1282
Failure Code [2G42ZG]1287
Failure Code [2G43ZG]1290
Failure Code [879AKA]1293
Failure Code [879AKB]1294
Failure Code [879BKA]1295
Failure Code [879BKB]1298
Failure Code [879CKA]1301
Failure Code [879CKB]1302
Failure Code [879DKZ]1303
Failure Code [879EMC]1307
Failure Code [879FMC]1308
Failure Code [879GKX]1309
Failure Code [989A00]1312
Failure Code [989L00]1313
Failure Code [989M00]1314
Failure Code [989N00]1315
Failure Code [A1U0N3]1316
Failure Code [A1U0N4]1320
Failure Code [AA10NX]1324
Failure Code [AB00KE]1327
Failure Code [AB00KY]1330
Failure Code [AQ10N3]1332
Failure Code [B@BAZG]1335
Failure Code [B@BAZK]1338
Failure Code [B@BCNS]1341
Failure Code [B@BCZK]1344
Failure Code [B@C6NS]1347
Failure Code [B@C7NS]1350
Failure Code [B@CENS]1353
Failure Code [B@GAZK]1356
Failure Code [B@HANS]1359
Failure Code [CA115]1362
Failure Code [CA122]1367
Failure Code [CA123]1370
Failure Code [CA131]1374
Failure Code [CA132]1377
Failure Code [CA135]1380
Failure Code [CA141]1383
Failure Code [CA144]1386
Failure Code [CA145]1389
Failure Code [CA153]1392
Failure Code [CA154]1396
Failure Code [CA187]1400
Failure Code [CA212]1404
Failure Code [CA213]1407
Failure Code [CA221]1410
Failure Code [CA222]1413
Failure Code [CA227]1417
Failure Code [CA234]1420
Failure Code [CA238]1422
Failure Code [CA239]1425
Failure Code [CA271]1428
Failure Code [CA272]1431
Failure Code [CA273]1433
Failure Code [CA274]1436
Failure Code [CA322]1438
Failure Code [CA323]1441
Failure Code [CA324]1444
Failure Code [CA325]1447
Failure Code [CA331]1450
Failure Code [CA332]1453
Failure Code [CA343]1456
Failure Code [CA351]1464
Failure Code [CA352]1472
Failure Code [CA356]1476
Failure Code [CA357]1480
Failure Code [CA386]1484
Failure Code [CA431]1488
Failure Code [CA432]1492
Failure Code [CA441]1497
Failure Code [CA442]1501
Failure Code [CA449]1505
Failure Code [CA451]1508
Failure Code [CA452]1511
Failure Code [CA515]1514
Failure Code [CA516]1516
Failure Code [CA553]1519
Failure Code [CA555]1522
Failure Code [CA556]1525
Failure Code [CA559]1528
Failure Code [CA595]1534
Failure Code [CA687]1537
Failure Code [CA689]1541
Failure Code [CA691]1546
Failure Code [CA692]1549
Failure Code [CA697]1552
Failure Code [CA698]1554
Failure Code [CA731]1556
Failure Code [CA778]1564
Failure Code [CA1117]1569
Failure Code [CA1135]1574
Failure Code [CA1257]1585
Failure Code [CA1664]1587
Loaded Diagnostics Operation to Clear Failure Code1589
Failure Code [CA1691]1591
Failure Code [CA1695]1596
Failure Code [CA1696]1599
Failure Code [CA1843]1602
Failure Code [CA1844]1605
Failure Code [CA1879]1608
Failure Code [CA1881]1612
Failure Code [CA1883]1616
Loaded Diagnostics Operation to Clear Failure Code1619
Failure Code [CA1921]1621
Failure Code [CA1922]1629
Failure Code [CA1923]1636
Failure Code [CA1924]1639
Diagram Related to Fuel Doser1642
Failure Code [CA1925]1644
Diagram Related to Fuel Doser1646
Failure Code [CA1927]1648
Failure Code [CA1928]1651
Failure Code [CA1942]1654
Failure Code [CA1963]1657
Diagram Related to Fuel Doser1663
Failure Code [CA1977]1665
Loaded Diagnostics Operation to Clear Failure Code1668
Failure Code [CA1993]1669
Loaded Diagnostics Operation to Clear Failure Code1671
Failure Code [CA2185]1673
Failure Code [CA2186]1676
Failure Code [CA2249]1679
Failure Code [CA2265]1686
Failure Code [CA2266]1689
Failure Code [CA2271]1692
Failure Code [CA2272]1695
Failure Code [CA2349]1699
Failure Code [CA2353]1702
Failure Code [CA2357]1704
Failure Code [CA2381]1709
Failure Code [CA2382]1712
Failure Code [CA2383]1716
Failure Code [CA2386]1720
Failure Code [CA2387]1722
Failure Code [CA2555]1732
Failure Code [CA2556]1735
Failure Code [CA2637]1738
Failure Code [CA2639]1745
Failure Code [CA2732]1753
Failure Code [CA2733]1756
Failure Code [CA2741]1759
Diagram Related to Fuel Doser1760
Failure Code [CA2765]1762
Failure Code [CA2777]1764
Failure Code [CA2878]1767
Diagram Related to Fuel Doser1771
Failure Code [CA2881]1773
Loaded Diagnostics Operation to Clear Failure Code1777
Failure Code [CA3133]1780
Failure Code [CA3134]1783
Failure Code [CA3135]1787
Loaded Diagnostics Operation to Clear Failure Code1790
Failure Code [CA3167]1792
How to Reset Fuel Doser Information1795
Failure Code [CA3251]1798
Loaded Diagnostics Operation to Clear Failure Code1805
Failure Code [CA3253]1806
Loaded Diagnostics Operation to Clear Failure Code1814
Failure Code [CA3254]1816
Loaded Diagnostics Operation to Clear Failure Code1823
Failure Code [CA3255]1825
Loaded Diagnostics Operation to Clear Failure Code1832
Failure Code [CA3256]1834
Loaded Diagnostics Operation to Clear Failure Code1841
Failure Code [CA3311]1843
Loaded Diagnostics Operation to Confirm Failure Correction1850
Failure Code [CA3312]1852
Loaded Diagnostics Operation to Confirm Failure Correction1859
Failure Code [CA3313]1861
Failure Code [CA3314]1864
Failure Code [CA3315]1867
Loaded Diagnostics Operation to Confirm Failure Correction1872
Failure Code [CA3316]1874
Failure Code [CA3317]1877
Failure Code [CA3318]1880
Loaded Diagnostics Operation to Confirm Failure Correction1885
Failure Code [CA3319]1887
Failure Code [CA3321]1890
Failure Code [CA3322]1893
Loaded Diagnostics Operation to Confirm Failure Correction1898
Failure Code [CA3419]1900
Failure Code [CA3421]1902
Failure Code [CA4151]1905
Failure Code [CA4158]1913
Failure Code [CA4161]1916
Failure Code [CA4162]1919
Failure Code [CA4163]1922
Loaded Diagnostics Operation to Confirm Failure Correction1924
Failure Code [CA4259]1925
Failure Code [CA4952]1928
Failure Code [CA5383]1931
Failure Code [CB115]1933
Failure Code [CB122]1938
Failure Code [CB123]1941
Failure Code [CB153]1945
Failure Code [CB154]1949
Failure Code [CB187]1953
Failure Code [CB227]1957
Failure Code [CB238]1960
Failure Code [CB239]1963
Failure Code [CB271]1966
Failure Code [CB272]1969
Failure Code [CB273]1971
Failure Code [CB274]1974
Failure Code [CB343]1976
Failure Code [CB351]1983
Failure Code [CB352]1991
Failure Code [CB356]1995
Failure Code [CB357]1999
Failure Code [CB386]2003
Failure Code [CB441]2006
Failure Code [CB442]2010
Failure Code [CB449]2014
Failure Code [CB451]2017
Failure Code [CB452]2020
Failure Code [CB515]2023
Failure Code [CB516]2025
Failure Code [CB553]2028
Failure Code [CB555]2031
Failure Code [CB556]2034
Failure Code [CB559]2037
Failure Code [CB595]2043
Failure Code [CB687]2046
Failure Code [CB689]2050
Failure Code [CB691]2055
Failure Code [CB692]2058
Failure Code [CB697]2061
Failure Code [CB698]2063
Failure Code [CB731]2065
Failure Code [CB778]2074
Failure Code [CB1117]2079
Failure Code [CB1257]2084
Failure Code [CB1548]2086
Failure Code [CB1549]2089
Failure Code [CB1551]2092
Failure Code [CB1552]2095
Failure Code [CB1553]2098
Failure Code [CB1622]2101
Failure Code [CB1664]2104
Loaded Diagnostics Operation to Clear Failure Code2107
Failure Code [CB1691]2108
Failure Code [CB1695]2113
Failure Code [CB1696]2116
Failure Code [CB1843]2119
Failure Code [CB1844]2122
Failure Code [CB1879]2125
Failure Code [CB1881]2129
Failure Code [CB1883]2133
Loaded Diagnostics Operation to Clear Failure Code2136
Failure Code [CB1921]2138
Failure Code [CB1922]2146
Failure Code [CB1923]2153
Failure Code [CB1924]2156
Diagram Related to Fuel Doser2159
Failure Code [CB1925]2161
Diagram Related to Fuel Doser2163
Failure Code [CB1927]2165
Failure Code [CB1928]2168
Failure Code [CB1942]2172
Failure Code [CB1963]2175
Diagram Related to Fuel Doser2181
Failure Code [CB1977]2183
Loaded Diagnostics Operation to Clear Failure Code2186
Failure Code [CB1993]2187
Loaded Diagnostics Operation to Clear Failure Code2189
Failure Code [CB2249]2191
Failure Code [CB2265]2197
Failure Code [CB2266]2200
Failure Code [CB2271]2203
Failure Code [CB2272]2206
Failure Code [CB2349]2210
Failure Code [CB2353]2213
Failure Code [CB2357]2215
Failure Code [CB2381]2220
Failure Code [CB2382]2223
Failure Code [CB2383]2227
Failure Code [CB2386]2231
Failure Code [CB2387]2233
Failure Code [CB2637]2243
Failure Code [CB2639]2250
Failure Code [CB2732]2259
Failure Code [CB2733]2262
Failure Code [CB2741]2265
Diagram Related to Fuel Doser2266
Failure Code [CB2765]2268
Failure Code [CB2777]2270
Failure Code [CB2878]2273
Diagram Related to Fuel Doser2277
Failure Code [CB2881]2279
Loaded Diagnostics Operation to Clear Failure Code2283
Failure Code [CB3133]2286
Failure Code [CB3134]2289
Failure Code [CB3135]2293
Loaded Diagnostics Operation to Clear Failure Code2296
Failure Code [CB3167]2298
How to Reset Fuel Doser Information2301
Failure Code [CB3251]2304
Loaded Diagnostics Operation to Clear Failure Code2311
Failure Code [CB3253]2312
Loaded Diagnostics Operation to Clear Failure Code2320
Failure Code [CB3254]2322
Loaded Diagnostics Operation to Clear Failure Code2329
Failure Code [CB3255]2331
Loaded Diagnostics Operation to Clear Failure Code2338
Failure Code [CB3256]2340
Loaded Diagnostics Operation to Clear Failure Code2347
Failure Code [CB3311]2349
Loaded Diagnostics Operation to Confirm Failure Correction2356
Failure Code [CB3312]2358
Loaded Diagnostics Operation to Confirm Failure Correction2365
Failure Code [CB3313]2367
Failure Code [CB3314]2370
Failure Code [CB3315]2373
Loaded Diagnostics Operation to Confirm Failure Correction2378
Failure Code [CB3316]2379
Failure Code [CB3317]2382
Failure Code [CB3318]2385
Loaded Diagnostics Operation to Confirm Failure Correction2390
Failure Code [CB3319]2392
Failure Code [CB3321]2395
Failure Code [CB3322]2398
Loaded Diagnostics Operation to Confirm Failure Correction2403
Failure Code [CB3419]2405
Failure Code [CB3421]2407
Failure Code [CB4151]2410
Failure Code [CB4158]2418
Failure Code [CB4161]2421
Failure Code [CB4162]2424
Failure Code [CB4163]2427
Loaded Diagnostics Operation to Confirm Failure Correction2429
Failure Code [CB4259]2430
Failure Code [CB4952]2433
Failure Code [CB5383]2436
Failure Code [D110L4]2438
Failure Code [D162KA]2441
Failure Code [D162KB]2442
Failure Code [D162KY]2443
Failure Code [D180KA]2444
Failure Code [D180KB]2447
Failure Code [D180KY]2450
Failure Code [D191KA]2452
Failure Code [D191KB]2455
Failure Code [D191KY]2458
Failure Code [D192KA]2460
Failure Code [D192KB]2463
Failure Code [D192KY]2466
Failure Code [D19JKZ]2468
Failure Code [D19LKA]2473
Failure Code [D19LKB]2476
Failure Code [D19LKY]2479
Failure Code [D1E6KA]2481
Failure Code [D1E6KB]2484
Failure Code [D1E6KY]2487
Failure Code [D1EFKA]2489
Failure Code [D1EFKB]2492
Failure Code [D1EFKY]2495
Failure Code [D1J0KB]2498
Failure Code [D5ZHKA]2501
Failure Code [D5ZHKB]2504
Failure Code [D5ZHKZ]2507
Failure Code [D5ZHL6]2511
Failure Code [D862KA]2514
Failure Code [DA80KY]2517
Failure Code [DA80L4]2520
Failure Code [DAF0KT]2524
Failure Code [DAF0MB]2525
Failure Code [DAF0MC]2526
Failure Code [DAF3KK]2527
Failure Code [DAF8KB]2531
Failure Code [DAFDKB]2534
Failure Code [DAFGMC]2537
Failure Code [DAFLKA]2538
Failure Code [DAFLKB]2541
Failure Code [DAFQKR]2544
Failure Code [DAQ0KK]2555
Failure Code [DAQ0KT]2560
Failure Code [DAQ0MC]2561
Failure Code [DAQ1KA]2562
Failure Code [DAQ2KK]2565
Failure Code [DAQ4KB]2569
Failure Code [DAQ9KQ]2572
Failure Code [DAQLKA]2574
Failure Code [DAQLKB]2577
Failure Code [DAQQKR]2580
Failure Code [DAQRKR]2595
Failure Code [DAQRMA]2609
Failure Code [DAZ9KQ]2610
Failure Code [DAZQKR]2612
Failure Code [DB2QKR]2623
Failure Code [DB2RKR]2641
Failure Code [DB90KK]2659
Failure Code [DB90KT]2664
Failure Code [DB90MC]2665
Failure Code [DB91KA]2666
Failure Code [DB92KK]2669
Failure Code [DB95KX]2674
Failure Code [DB96KX]2677
Failure Code [DB97KX]2682
Failure Code [DB99KQ]2685
Failure Code [DB9LKA]2687
Failure Code [DB9LKB]2690
Failure Code [DB9QKR]2693
Failure Code [DB9RKR]2709
Failure Code [DB9RMA]2725
Failure Code [DBE5KX]2727
Failure Code [DBE6KX]2730
Failure Code [DBE7KX]2733
Failure Code [DBP0KM]2737
Failure Code [DBP0KT]2739
Failure Code [DBP0NR]2740
Failure Code [DBP5KP]2741
Failure Code [DBPLKA]2745
Failure Code [DBPLKB]2749
Failure Code [DBPQKR]2752
Failure Code [DBPRKR]2766
Failure Code [DBPRMA]2779
Failure Code [DBPUKR]2780
Failure Code [DBPVKR]2790
Failure Code [DBPWKR]2798
Failure Code [DBPXKR]2800
Failure Code [DBV0MC]2802
Failure Code [DBV1KK]2803
Failure Code [DBV5KX]2808
Failure Code [DBV6KX]2812
Failure Code [DBV7KX]2816
Failure Code [DBV8KX]2817
Failure Code [DBVLKA]2818
Failure Code [DBVLKB]2822
Failure Code [DBVQK4]2825
Failure Code [DBVQKR]2839
Failure Code [DBVRKR]2853
Failure Code [DBVVKR]2867
Failure Code [DBVWKR]2868
Failure Code [DD1ALD]2870
Failure Code [DDA8KB]2873
Failure Code [DDA9KB]2876
Failure Code [DDAAL6]2879
Failure Code [DDACKA]2883
Failure Code [DDACKY]2888
Failure Code [DDADKA]2892
Failure Code [DDADKY]2896
Failure Code [DDB6L4]2898
Failure Code [DDD1LD]2902
Failure Code [DDDBKA]2905
Failure Code [DDDBKY]2909
Failure Code [DDE2KB]2912
Failure Code [DDE2L6]2915
Failure Code [DDE5KA]2917
Failure Code [DDK4KA]2920
Failure Code [DDK4KB]2924
Failure Code [DDK5L4]2928
Failure Code [DDNRKY]2931
Failure Code [DDNTKY]2934
Failure Code [DDNUKY]2937
Failure Code [DDNWKY]2940
Failure Code [DDNYKB]2942
Failure Code [DDP5KA]2945
Failure Code [DDP6KA]2948
Failure Code [DDP6KY]2951
Failure Code [DDP6NR]2954
Failure Code [DDW9LD]2956
Failure Code [DDWLLD]2959
Failure Code [DF10KA]2962
Failure Code [DF10KB]2963
Failure Code [DGE5KA]2964
Failure Code [DGE5KB]2967
Failure Code [DGF1KA]2970
Failure Code [DGF1KB]2973
Failure Code [DGH2KX]2976
Failure Code [DGR2KB]2979
Failure Code [DGR2KZ]2983
Failure Code [DGR4KB]2987
Failure Code [DGR4KZ]2991
Failure Code [DGT1KA]2995
Failure Code [DGT1KB]2998
Failure Code [DGT5KA]3001
Failure Code [DGT5KY]3006
Failure Code [DGT6KA]3010
Failure Code [DGT6KY]3015
Failure Code [DH21KA]3019
Failure Code [DH21KY]3023
Failure Code [DHA4KA]3026
Failure Code [DHAAMA]3029
Failure Code [DHABMA]3031
Failure Code [DHACMA]3033
Failure Code [DHADMA]3035
Failure Code [DHPAKA]3037
Failure Code [DHPAKY]3041
Failure Code [DHPCKA]3044
Failure Code [DHPCKY]3048
Failure Code [DHPDKA]3051
Failure Code [DHPDKY]3055
Failure Code [DHPSKA]3058
Failure Code [DHPSKY]3062
Failure Code [DHT2L6]3065
Failure Code [DHT3KX]3068
Failure Code [DHT5KX]3072
Failure Code [DHT7KX]3076
Failure Code [DHT8KA]3080
Failure Code [DHT8KY]3083
Failure Code [DHTAKX]3085
Failure Code [DHTBKA]3089
Failure Code [DHTBKY]3093
Failure Code [DHU2KA]3096
Failure Code [DHU2KY]3099
Failure Code [DHU3KA]3102
Failure Code [DHU3KY]3105
Failure Code [DJF1KA]3108
Failure Code [DK30KA]3111
Failure Code [DK30KY]3115
Failure Code [DK55KA]3118
Failure Code [DK55KY]3119
Failure Code [DK55L5]3120
Failure Code [DK59KA]3121
Failure Code [DK59KY]3125
Failure Code [DK59L8]3128
Failure Code [DK5AKA]3133
Failure Code [DK5AKY]3137
Failure Code [DK5BKA]3140
Failure Code [DK5BKY]3144
Failure Code [DK5BL8]3147
Failure Code [DK5CKA]3151
Failure Code [DK5CKY]3155
Failure Code [DKA0KA]3158
Failure Code [DKA0KY]3162
Failure Code [DKA0L0]3165
Failure Code [DKA1KA]3168
Failure Code [DKA1KY]3172
Failure Code [DKD0KA]3175
Failure Code [DKD0KY]3178
Failure Code [DKD0L8]3180
Failure Code [DKR2KX]3182
Failure Code [DKR2NX]3186
Failure Code [DKR3KX]3189
Failure Code [DKR3NX]3193
Failure Code [DLFAKA]3196
Failure Code [DLFALC]3199
Failure Code [DLFFLC]3202
Failure Code [DLM3KA]3206
Failure Code [DLM3LC]3209
Failure Code [DLT3KA]3212
Failure Code [DLT3LC]3215
Failure Code [DLT4KB]3218
Failure Code [DLT4KX]3221
Failure Code [DNDBL4]3224
Failure Code [DPQ1KR]3227
Failure Code [DPQ1LD]3233
Failure Code [DPQ2KR]3239
Failure Code [DPQ3KR]3246
Failure Code [DPQ4KB]3252
Failure Code [DQ11KQ]3254
Sensor Addresses List3258
Failure Code [DQ11KR]3259
Failure Code [DQ11KT]3262
Failure Code [DQ11MA]3265
Failure Code [DQ11NR]3269
Failure Code [DQ12KQ]3272
Sensor Addresses List3276
Failure Code [DQ12KR]3277
Failure Code [DQ12KT]3280
Failure Code [DQ12MA]3283
Failure Code [DQ12NR]3287
Failure Code [DQ13KQ]3290
Sensor Addresses List3294
Failure Code [DQ13KR]3295
Failure Code [DQ13KT]3298
Failure Code [DQ13MA]3301
Failure Code [DQ13NR]3305
Failure Code [DQ14KQ]3308
Sensor Addresses List3312
Failure Code [DQ14KR]3313
Failure Code [DQ14KT]3316
Failure Code [DQ14MA]3319
Failure Code [DQ14NR]3324
Failure Code [DR10KA]3327
Failure Code [DR20KA]3331
Failure Code [DR30KA]3335
Failure Code [DR40KA]3339
Failure Code [DR50KA]3343
Failure Code [DR60KA]3347
Failure Code [DSJ0KR]3351
Failure Code [DT22KB]3361
Failure Code [DUMBKB]3364
Failure Code [DV00KB]3367
Failure Code [DV01KB]3370
Failure Code [DW4PKA]3373
Failure Code [DW4PKB]3376
Failure Code [DW4PKY]3379
Failure Code [DW4QKA]3382
Failure Code [DW4QKB]3385
Failure Code [DW4QKY]3388
Failure Code [DW4RKA]3391
Failure Code [DW4RKB]3394
Failure Code [DW4RKY]3397
Failure Code [DW4SKA]3400
Failure Code [DW4SKB]3403
Failure Code [DW4SKY]3406
Failure Code [DW5PKA]3409
Failure Code [DW5PKB]3412
Failure Code [DW5PKY]3415
Failure Code [DW5QKA]3418
Failure Code [DW5QKB]3421
Failure Code [DW5QKY]3424
Failure Code [DW5RKA]3427
Failure Code [DW5RKB]3430
Failure Code [DW5RKY]3433
Failure Code [DW5SKA]3436
Failure Code [DW5SKB]3439
Failure Code [DW5SKY]3442
Failure Code [DW7BKA]3445
Failure Code [DW7BKB]3448
Failure Code [DW7BKY]3451
Failure Code [DWM1KA]3453
Failure Code [DWM1KB]3456
Failure Code [DWM1KY]3459
Failure Code [DWN6KA]3461
Failure Code [DWN6KB]3464
Failure Code [DWN6KY]3467
Failure Code [DWN8KA]3470
Failure Code [DWN8KB]3473
Failure Code [DWN8KY]3476
Failure Code [DWNFKA]3479
Failure Code [DWNFKB]3482
Failure Code [DWNFKY]3485
Failure Code [DWNVKA]3487
Failure Code [DWNVKB]3490
Failure Code [DWNVKY]3493
Failure Code [DX16KA]3495
Failure Code [DX16KB]3498
Failure Code [DX16KY]3501
Failure Code [DXA1KA]3503
Failure Code [DXA1KB]3506
Failure Code [DXA1KY]3509
Failure Code [DXA8KA]3511
Failure Code [DXA8KB]3514
Failure Code [DXA8KY]3517
Failure Code [DXANKA]3519
Failure Code [DXANKB]3522
Failure Code [DXANKY]3525
Failure Code [DXF0KA]3527
Failure Code [DXF0KB]3530
Failure Code [DXF0KY]3533
Failure Code [DXF5KA]3535
Failure Code [DXF5KB]3538
Failure Code [DXF5KY]3541
Failure Code [DXF6KA]3543
Failure Code [DXF6KB]3546
Failure Code [DXF6KY]3549
Failure Code [DXH4KA]3551
Failure Code [DXH4KB]3554
Failure Code [DXH4KY]3557
Failure Code [DXH5KA]3559
Failure Code [DXH5KB]3562
Failure Code [DXH5KY]3565
Failure Code [DXH6KA]3567
Failure Code [DXH6KB]3570
Failure Code [DXH6KY]3573
Failure Code [DXH7KA]3575
Failure Code [DXH7KB]3578
Failure Code [DXH7KY]3581
Failure Code [DXH8KA]3583
Failure Code [DXH8KB]3586
Failure Code [DXH8KY]3589
Failure Code [DXHPKA]3591
Failure Code [DXHPKB]3594
Failure Code [DXHPKY]3597
Failure Code [DXHPMA]3600
Failure Code [DXHPMB]3603
Troubleshooting of Electrical System (E-Mode)3606
Engine Does Not Start (Engine Does Not Crank)3606
Manual Preheating System Does Not Operate3621
Automatic Preheating System Does Not Work (For Machines Without Pre-lubrication System)3629
Automatic Preheating System Does Not Work (For Machines with Pre-lubrication System)3636
While Preheating is in Operation, Preheating Pilot Lamp Does Not Come On3643
LCD Unit, LED Unit, and Meter Unit on Machine Monitor Do Not Show Anything3647
LCD Unit on Machine Monitor Shows Nothing3657
Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers)3660
LCD Screen on Machine Monitor Does Not Show Correctly3663
Meter Unit Display on Machine Monitor is Abnormal3666
Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal3671
LED Unit Lamp on Machine Monitor is Abnormal3675
Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly3680
Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate3685
Switch Panel Buzzer of Machine Monitor is Abnormal3690
Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Correctly3695
Rearview Monitor Does Not Come On or Backlight Flickers3696
Rearview Monitor Images are Not Shown Clearly3701
Rearview Monitor Brightness Cannot be Adjusted3707
Night Mode Lamp of Rearview Monitor is Abnormal3713
Air Cleaner Clogging Caution Lamp Does Not Come On3717
Radiator Coolant Level Caution Lamp Does Not Come On3720
Parking Brake Indicator Lamp Does Not Come On When Parking Brake is ON (Parking) Position3723
Brake Oil Pressure Caution Lamp Does Not Come On When Front Brake Accumulator Oil Pressure is Low3732
Brake Oil Pressure Caution Lamp Does Not Come On When Rear Brake Accumulator Oil Pressure is Low3736
Fuel Gauge Does Not Show Normally3740
Torque Converter Oil Temperature Gauge Does Not Rise or Torque Converter Oil Temperature Caution Lamp Does Not Come On3743
Hydraulic Oil Temperature Gauge Does Not Rise or Hydraulic Oil Temperature Caution Lamp Does Not Come On3745
Seatbelt Caution Lamp Does Not Show Normally3747
Alarm Buzzer Does Not Operate3750
Alarm Buzzer Does Not Stop3752
Kickdown Does Not Operate When Kickdown Switch is ON Position3754
Hold Does Not Operate When Hold Switch is on Position3757
Parking Brake Does Not Operate Even If It is Applied, or the Brake Drags in FORWARD or REVERSE Travel When Parking Brake is Released3760
Loader Pump1 or Loader Pump 2 is Fixed to the Minimum Flow3768
ECSS Function Cannot be Selected or Cannot be Released3771
Horn Does Not Sound3774
Horn Does Not Stop3779
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On3782
Clearance Lamp and Tail Lamp Do Not Come On or Go Out3786
Headlamp Do Not Come On or Go Out3792
Side Working Lamp Does Not Come On or Go Out3798
Front Working Lamp Does Not Come On or Go Out3803
Rear Working Lamp Does Not Come On or Go Out3810
Turn Signal Lamp and Hazard Lamp Do Not Come On or Go Out3817
Turn Signal Lamp Does Not Come On or Go Out3823
Hazard Lamp Does Not Come On or Go Out3830
Brake Lamp Does Not Come On or Stays Lit3836
Backup Lamp Does Not Come On or Stays Lit3841
Staircase Light Does Not Come On or Go Out3845
Engine Room Lamp Does Not Come On or Go Out3851
Fog Lamp Does Not Come On or Go Out3856
Yellow Revolving Lamp Does Not Come On or Go Out3861
Backup Buzzer Does Not Sound or Continues to Sound3866
Front Wiper Does Not Operate3870
Rear Wiper Does Not Operate3875
Side Wiper Does Not Operate3880
Fuel Feed Pump Does Not Operate or Stop Automatically3885
Front Window Washer Does Not Operate3893
Rear Window Washer Does Not Operate3897
Side Window Washer Does Not Operate3901
Power Ladder Does Not Operate3905
Shock is Large When Power Ladder Stops3912
Parking Status Cannot be Cancelled While Power Ladder is Stored3916
Auto-Digging Function Does Not Operate3919
Semi-Auto Approach Function Does Not Operate3923
Semi-Auto Dump Function Does Not Operate3927
KOMTRAX Plus System Does Not Operate Normally3932
Data Download with Wireless LAN Does Not Operate3935
KomVision Monitor Does Not Come On or Backlight Flickers3936
KomVision Monitor Images are Not Shown Clearly3941
KomVision Monitor Brightness Cannot be Adjusted3949
Night Mode Lamp of KomVision Monitor is Abnormal3955
A Part of Camera Image of KomVision Monitor is Not Shown3959
KomVision Monitor is Not Shown Correctly After Calibration3961
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)3963
Information Shown in Troubleshooting Table (H-Mode)3963
Failure Mode and Cause Table3964
Machine Does Not Start3978
ECMV Operation Table3986
Travel Speed is Slow, Bucket Thrust Force is Weak, Gradability is Low, or Gear Speed Does Not Shift3987
ECMV Operation Table3994
Strong Shocks are Made When You Start Machine or Shift Gears3995
ECMV Operation Table4000
Time Lag is Large When You Start Machine or Shift Gears4001
ECMV Operation Table4006
Torque Converter Oil Temperature is High4007
Machine Does Not Turn4013
Turning Response is Unsatisfactory4019
Machine Sways or Large Shocks are Made While Machine Turns4025
Wheel Brakes Do Not Operate or are Weak4030
Wheel Brakes are Not Released or Drag4034
Parking Brake Does Not Operate or is Weak4036
Parking Brake is Not Released or Drags4038
Boom Does Not Rise4042
Boom Moves Slow or Lacks Lifting Force4048
Rising Boom Slows Down at Specified Height4054
Lift Cylinders Can Not Hold Bucket on Ground4055
Hydraulic Drift of Boom is Large4059
Boom Moves Up and Down During Operation4061
Bucket Does Not Tilt Back4064
Bucket Moves Slow or Lacks Tilt-Back Force4071
Bucket Slows Down During Tilt Back Operation4078
Bucket Cylinder Does Not Hold Bucket on Ground4079
Hydraulic Drift of Bucket is Large4083
Bucket Tilts Back and Forth When You Carry Load4085
Boom and Bucket Control Levers Do Not Move Smoothly and are Heavy to Move4088
Engine Speed Drops Largely or Engine Stops When You Operate Work Equipment4090
Large Shocks are Made When Work Equipment Starts to Move and Stops4094
When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves4101
ECSS Does Not Operate and Machine Pitches and Bounces4102
Fan Speed is Abnormal (Too High or Low, or Does Not Move)4105
Unusual Noise is Heard from Around Fan4109
Troubleshooting of Engine (S-Mode)4110
Information Shown in Troubleshooting Table (S-Mode)4110
Engine Does Not Crank When Starting Switch is Turned to Start Position4111
Engine Cranks but Does Not Start4113
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)4118
Engine Startability is Unsatisfactory4125
Engine Does Not Pick Up Smoothly4131
Engine Stops During Operation4138
Engine Does Not Rotate Smoothly4145
Engine Lacks Output (or Lacks Power)4151
KDPF Becomes Clogged in a Short Time4158
Engine Oil Consumption is Excessive4163
Engine Oil Becomes Dirty Quickly4167
Fuel Consumption is Excessive4171
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)4175
Engine Oil Pressure Drops4177
Fuel Mixes Into Engine Oil4181
Water Mixes Into Engine Oil (Milky)4183
Coolant Temperature Increases Too High (Overheat)4186
Unusual Noise is Heard4191
Vibration is Excessive4194
Air Cannot be Bled from Fuel Circuit4196
Active Regeneration is Done Frequently4200
Active Regeneration Continues Long4206
White Smoke is Exhausted During Active Regeneration4211
50 Disassembly and Assembly4213
Table of Contents4214
Precautions Before Work4221
Related Information on Disassembly and Assembly4222
How to Read This Manual4222
Coating Materials List4224
Special Tool List4229
Sketches of Special Tools4247
Engine and Cooling System4260
Remove and Install Supply Pump Assembly (Right Bank)4260
How to Remove Supply Pump Assembly (Right Bank)4261
How to Install Supply Pump Assembly (Right Bank)4272
Remove and Install Supply Pump Assembly (Left Bank)4291
How to Remove Supply Pump Assembly (Left Bank)4292
How to Install Supply Pump Assembly (Left Bank)4298
Remove and Install Injector Assembly (Right Bank)4309
How to Remove Injector Assembly (Right Bank)4310
How to Install Injector Assembly (Right Bank)4320
Remove and Install Injector Assembly (Left Bank)4333
How to Remove Injector Assembly (Left Bank)4334
How to Install Injector Assembly (Left Bank)4344
Remove and Install Fuel Doser Assembly (Right Bank)4357
How to Remove Fuel Doser Assembly (Right Bank)4357
How to Install Fuel Doser Assembly (Right Bank)4360
Remove and Install Fuel Doser Assembly (Left Bank)4364
How to Remove Fuel Doser Assembly (Left Bank)4364
How to Install Fuel Doser Assembly (Left Bank)4367
Remove and Install Cylinder Head Assembly (Right Bank)4371
How to Remove Cylinder Head Assembly (Right Bank)4374
How to Install Cylinder Head Assembly (Right Bank)4404
Remove and Install Cylinder Head Assembly (Left Bank)4449
How to Remove Cylinder Head Assembly (Left Bank)4452
How to Install Cylinder Head Assembly (Left Bank)4485
Remove and Install EGR Valve Assembly (Right Bank)4537
How to Remove EGR Valve Assembly (Right Bank)4538
How to Install EGR Valve Assembly (Right Bank)4548
Remove and Install EGR Valve Assembly (Left Bank)4561
How to Remove EGR Valve Assembly (Left Bank)4562
How to Install EGR Valve Assembly (Left Bank)4572
Remove and Install EGR Cooler Assembly (Right Bank)4586
How to Remove EGR Cooler Assembly (Right Bank)4587
How to Install EGR Cooler Assembly (Right Bank)4602
Remove and Install EGR Cooler Assembly (Left Bank)4624
How to Remove EGR Cooler Assembly (Left Bank)4625
How to Install EGR Cooler Assembly (Left Bank)4641
Remove and Install Starter Assembly4663
How to Remove Starting Motor Assembly4663
How to Install Starting Motor Assembly4666
Remove and Install Alternator Belt4669
How to Remove Alternator Belt4670
How to Install Alternator Belt4671
Remove and Install Alternator Assembly4674
How to Remove Alternator Assembly4675
How to Install Alternator Assembly4677
Remove and Install Cooler Assembly4682
How to Remove Cooling Assembly4684
How to Install Cooling Assembly4700
Remove and Install Radiator Core4718
How to Remove Radiator Core4719
How to Install Radiator Core4726
Remove and Install Radiator Reservoir Tank Assembly4733
How to Remove Radiator Reservoir Tank Assembly4734
How to Install Radiator Reservoir Tank Assembly4735
Remove and Install Cooling Fan and Fan Motor Assembly4737
How to Remove Cooling Fan and Fan Motor Assembly4738
How to Install Cooling Fan and Fan Motor Assembly4742
Remove and Install Hydraulic Oil Cooler Assembly4746
How to Remove Hydraulic Oil Cooler Assembly4746
How to Install Hydraulic Oil Cooler Assembly4748
Remove and Install Aftercooler Assembly4750
How to Remove Aftercooler Assembly4751
How to Install Aftercooler Assembly4756
Remove and Install Power Train Oil Cooler Assembly4761
How to Remove Power Train Oil Cooler Assembly4762
How to Install Power Train Oil Cooler Assembly4763
Remove and Install Brake Cooler4765
How to Remove Brake Cooler4766
How to Install Brake Cooler4767
Remove and Install Engine Assembly4768
How to Remove Engine Assembly4770
How to Install Engine Assembly4784
Remove and Install Engine Front Oil Seal4799
How to Remove Engine Front Oil Seal4799
How to Install Engine Front Oil Seal4801
Remove and Install Engine Rear Oil Seal4803
How to Remove Engine Rear Oil Seal4804
How to Install Engine Rear Oil Seal4805
Remove and Install Upper Part of Engine4808
How to Remove Upper Part of Engine4809
How to Install Upper Part of Engine4814
Remove and Install Top Hood Assembly4819
How to Remove Top Hood Assembly4819
How to Install Top Hood Assembly4821
Remove and Install Fuel Tank Assembly4824
How to Remove Fuel Tank Assembly4825
How to Install Fuel Tank Assembly4831
Remove and Install KDPF Assembly4836
How to Remove KDPF Assembly4837
How to Install KDPF Assembly4843
Disassemble and Assemble KDPF Assembly4851
How to Disassemble KDPF Assembly4852
How to Assemble KDPF Assembly4858
Remove and Install KCCV Assembly (Right Bank)4867
How to Remove KCCV Assembly (Right Bank)4867
How to Install KCCV Assembly (Right Bank)4871
Remove and Install KCCV Assembly (Left Bank)4875
How to Remove KCCV Assembly (Left Bank)4876
How to Install KCCV Assembly (Left Bank)4880
Remove and Install VGT Assembly (Right Bank)4885
How to Remove VGT Assembly (Right Bank)4886
How to Install VGT Assembly (Right Bank)4897
Remove and Install VGT Assembly (Left Bank)4910
How to Remove VGT Assembly (Left Bank)4911
How to Install VGT Assembly (Left Bank)4922
Remove and Install Air Cleaner Assembly4935
How to Remove Air Cleaner Assembly4935
How to Install Air Cleaner Assembly4937
Remove and Install Air Conditioner Compressor Assembly4939
How to Remove Air Conditioner Compressor Assembly4940
How to Install Air Conditioner Compressor Assembly4942
Remove and Install Air Conditioner Condenser Assembly4946
How to Remove Air Conditioner Condenser Assembly4946
How to Install Air Conditioner Condenser Assembly4949
Drain and Add Coolant4952
How to Drain Coolant4952
How to Add Coolant4954
Power Train4956
Remove and Install Damper Assembly4956
How to Remove Damper Assembly4958
How to Install Damper Assembly4961
Disassemble and Assemble Damper Assembly4963
How to Disassemble Damper Assembly4964
How to Assemble Damper Assembly4965
Remove and Install Transmission, Transfer Assembly and Torque Converter, Input Transfer, PTO Assembly4971
How to Remove Transmission, Transfer Assembly and Torque Converter, Input Transfer, PTO Assembly4975
How to Install Transmission, Transfer Assembly and Torque Converter, Input Transfer, PTO Assembly5000
Disconnect and Connect Transmission, Transfer Assembly and Torque Converter, Input Transfer, PTO Assembly5026
How to Disconnect Transmission, Transfer Assembly and Torque Converter, Input Transfer, PTO Assembly5027
How to Connect Transmission, Transfer Assembly and Torque Converter, Input Transfer, PTO Assembly5032
Disconnect and Connect Torque Converter, Input Transfer and PTO Assembly5040
How to Disconnect Torque Converter, Input Transfer, PTO Assembly5041
How to Connect Torque Converter, Input Transfer, PTO Assembly5043
Disassemble and Assemble Torque Converter Assembly5046
How to Disassemble Torque Converter Assembly5047
How to Assemble Torque Converter Assembly5049
Disassemble and Assemble Input Transfer and PTO Assembly5054
How to Disassemble Input Transfer and PTO Assembly5056
How to Assemble Input Transfer and PTO Assembly5067
Disconnect and Connect Transmission and Transfer Assembly5089
How to Disconnect Transmission and Transfer Assembly5089
How to Connect Transmission and Transfer Assembly5090
Disassemble and Assemble Transmission Assembly5092
How to Disassemble Transmission Assembly5094
How to Assemble Transmission Assembly5107
Disassemble and Assemble Transfer Assembly5122
How to Disassemble Transfer Assembly5124
How to Assemble Transfer Assembly5132
Remove and Install Parking Brake Assembly5146
How to Remove Parking Brake Assembly5147
How to Install Parking Brake Assembly5151
Disassemble and Assemble Parking Brake Assembly5154
How to Disassemble Parking Brake Assembly5155
How to Assemble Parking Brake Assembly5157
Drain and Add Transmission Oil5161
How to Drain Transmission Oil5161
How to Add Transmission Oil5162
Remove and Install Front Axle Assembly5163
How to Remove Front Axle Assembly5165
How to Install Front Axle Assembly5172
Remove and Install Rear Axle Assembly5178
How to Remove Rear Axle Assembly5180
How to Install Rear Axle Assembly5188
Remove and Install Center Support Assembly5196
How to Remove Center Support Assembly5197
How to Install Center Support Assembly5199
Disassemble and Assemble Center Support Assembly5203
How to Disassemble Center Support Assembly5203
How to Assemble Center Support Assembly5205
Remove and Install Differential Assembly5210
How to Remove Differential Assembly5211
How to Install Differential Assembly5214
Disassemble and Assemble Differential Assembly5218
How to Disassemble Differential Assembly5220
How to Assemble Differential Assembly5230
Remove and Install Final Drive Carrier Assembly5252
How to Remove Final Drive Carrier Assembly5253
How to Install Final Drive Carrier Assembly5254
Disassemble and Assemble Final Drive Carrier Assembly5257
How to Disassemble Final Drive Carrier Assembly5257
How to Assemble Final Drive Carrier Assembly5259
Remove and Install Front Final Drive and Brake Assembly5262
How to Remove Front Final Drive and Brake Assembly5263
How to Install Front Final Drive and Brake Assembly5266
Disassemble and Assemble Final Drive and Brake Assembly5271
How to Disassemble Final Drive and Brake Assembly5273
How to Assemble Final Drive and Brake Assembly5282
Steering System5299
Remove and Install Steering Valve Assembly5299
How to Remove Steering Valve Assembly5300
How to Install Steering Valve Assembly5308
Remove and Install Rotary Valve Assembly5317
How to Remove Rotary Valve Assembly5318
How to Install Rotary Valve Assembly5320
Brake System5323
Remove and Install Right Brake Valve Assembly5323
How to Remove Right Brake Valve Assembly5324
How to Install Right Brake Valve Assembly5327
Remove and Install Left Brake Valve Assembly5332
How to Remove Left Brake Valve Assembly5333
How to Install Left Brake Valve Assembly5336
Remove and Install Brake Accumulator Assembly5339
How to Remove Brake Accumulator Assembly5340
How to Install Brake Accumulator Assembly5343
Undercarriage and Frame5346
Remove and Install Front Wheel Assembly5346
How to Remove Front Wheel Assembly5346
How to Install Front Wheel Assembly5349
Remove and Install Rear Wheel Assembly5351
How to Remove Rear Wheel Assembly5352
How to Install Rear Wheel Assembly5357
Remove and Install Center Hinge Pin5363
How to Remove Center Hinge Pin5367
How to Install Center Hinge Pin5378
Remove and Install Bumper Assembly5396
How to Remove Bumper Assembly5397
How to Install Bumper Assembly5400
Hydraulic System5403
Remove and Install Hydraulic Tank Assembly5403
How to Remove Hydraulic Tank Assembly5404
How to Install Hydraulic Tank Assembly5412
Remove and Install Work Equipment Pump, Pilot and Brake Charge Pump Assembly5419
How to Remove Work Equipment Pump, Pilot and Brake Charge Pump Assembly5420
How to Install Work Equipment Pump, Pilot and Brake Charge Pump Assembly5425
Remove and Install Work Equipment Pump and Brake Cooling Duplex Pump Assembly5429
How to Remove Work Equipment Pump and Brake Cooling Duplex Pump Assembly5430
How to Install Work Equipment Pump and Brake Cooling Duplex Pump Assembly5434
Remove and Install Secondary Steering Pump Assembly5438
How to Remove Secondary Steering Pump Assembly5439
How to Install Secondary Steering Pump Assembly5440
Remove and Install Steering Pump Assembly5442
How to Remove Steering Pump Assembly5443
How to Install Steering Pump Assembly5449
Remove and Install Cooling Pump and Cooling Fan Pump Assembly5454
How to Remove Cooling Pump and Cooling Fan Pump Assembly5455
How to Install Cooling Pump and Cooling Fan Pump Assembly5460
Remove and Install Transmission and Torque Converter Lubrication Triplex Pump Assembly5466
How to Remove Transmission and Torque Converter Lubrication Triplex Pump Assembly5467
How to Install Transmission and Torque Converter Lubrication Triplex Pump Assembly5469
Remove and Install Control Valve Assembly5471
How to Remove Control Valve Assembly5472
How to Install Control Valve Assembly5484
Remove and Install Diverter Valve Assembly5496
How to Remove Diverter Valve Assembly5497
How to Install Diverter Valve Assembly5500
Drain and Add Hydraulic Oil5503
How to Drain Hydraulic Oil5503
How to Add Hydraulic Oil5505
Work Equipment5506
Remove and Install Work Equipment Assembly5506
How to Remove Work Equipment Assembly5507
How to Install Work Equipment Assembly5514
Disassemble and Assemble Steering Cylinder Assembly5522
How to Disassemble Steering Cylinder Assembly5523
How to Assemble Steering Cylinder Assembly5525
Disassemble and Assemble Bucket Cylinder Assembly5529
How to Disassemble Bucket Cylinder Assembly5530
How to Assemble Bucket Cylinder Assembly5532
Disassemble and Assemble Lift Cylinder Assembly5536
How to Disassemble Lift Cylinder Assembly5537
How to Assemble Lift Cylinder Assembly5539
Remove and Install Boom End (Bucket Hinge) Bushing5543
How to Remove Boom End (Bucket Hinge) Bushing5543
How to Install Boom End (Bucket Hinge) Bushing5544
CAB Related Parts5545
Remove and Install ROPS Assembly5545
How to Remove ROPS Assembly5546
How to Install ROPS Assembly5550
Remove and Install Operator CAB Assembly and Floor Frame Assembly5555
How to Remove Operator Cab Assembly and Floor Frame Assembly5557
How to Install Operator Cab Assembly and Floor Frame Assembly5567
Remove and Install Operator Cab Assembly5578
How to Remove Operator Cab Assembly5579
How to Install Operator Cab Assembly5594
Remove and Install Operator Cab Glass (Adhered Glass)5608
How to Remove Operator Cab Glass (Adhered Glass)5608
How to Install Operator Cab Glass (Adhered Glass)5609
Remove and Install Air Conditioner Unit Assembly5618
How to Remove Air Conditioner Unit Assembly5619
How to Install Air Conditioner Unit Assembly5625
Remove and Install Operator Seat Assembly5633
How to Remove Operator Seat Assembly5633
How to Install Operator Seat Assembly5636
Remove and Install Work Equipment Control Lever5640
How to Remove Work Equipment Control Lever5641
How to Install Work Equipment Control Lever5644
How to Remove and Install Seat Belt5648
How to Remove Seat Belt5648
How to Install Seatbelt5649
Remove and Install AJSS Lever Switch Assembly5651
How to Remove AJSS Lever Switch Assembly5652
How to Install AJSS Lever Switch Assembly5656
Electrical System5662
Remove and Install Engine Controller Assembly (Right Bank)5662
How to Remove Engine Controller Assembly (Right Bank)5663
How to Install Engine Controller Assembly (Right Bank)5665
Remove and Install Engine Controller Assembly (Left Bank)5669
How to Remove Engine Controller Assembly (Left Bank)5670
How to Install Engine Controller Assembly (Left Bank)5672
Remove and Install Work Equipment Controller Assembly5676
How to Remove Work Equipment Controller Assembly5677
How to Install Work Equipment Controller Assembly5680
Remove and Install Transmission Controller Assembly5683
How to Remove Transmission Controller Assembly5684
How to Install Transmission Controller Assembly5687
Remove and Install Monitor Controller Assembly5690
How to Remove Monitor Controller Assembly5691
How to Install Monitor Controller Assembly5694
Remove and Install Machine Monitor Assembly5697
How to Remove Machine Monitor Assembly5697
How to Install Machine Monitor Assembly5699
Remove and Install Mass Air Flow and Temperature Sensor5702
How to Remove Mass Air Flow and Temperature Sensor5702
How to Install Mass Air Flow and Temperature Sensor5703
Remove and Install KCCV Crankcase Pressure Sensor5704
How to Remove KCCV Crankcase Pressure Sensor5704
How to Install KCCV Crankcase Pressure Sensor5707
Remove and Install KDPF Temperature Sensor5711
How to Remove KDPF Temperature Sensor5711
How to Install KDPF Temperature Sensor5718
Remove and Install KDPF Differential Pressure Sensor5723
How to Remove KDPF Differential Pressure Sensor5723
How to Install KDPF Differential Pressure Sensor5728
Remove and Install KomVision Camera Assembly5733
How to Remove KomVision Camera Assembly5735
How to Install KomVision Camera Assembly5745
Remove and Install KomVision Radar Assembly5756
How to Remove KomVision Radar Assembly5758
How to Install KomVision Radar Assembly5761
Remove and Install KomVision Controller5764
How to Remove KomVision Controller5764
How to Install KomVision Controller5766
Remove And Install KOMTRAX Plus Controller Assembly5768
How to Remove KOMTRAX Plus Controller Assembly5768
How to Install KOMTRAX Plus Controller Assembly5770
Remove and Install Wireless LAN Unit Assembly5772
How to Remove Wireless LAN Unit Assembly5772
How to Install Wireless LAN Unit Assembly5774
60 Maintenance Standard5777
Table of Contents5778
Explanation of Terms for Maintenance Standard5779
Engine and Cooling System5781
Maintenance Standard for Engine Mount5781
Maintenance Standard for Damper5782
Maintenance Standard for Cooling Fan Pump5784
Maintenance Standard for Servo Valve for Cooling Fan Pump5786
Maintenance Standard for Cooling Fan Motor5787
Power Train5790
Maintenance Standard for Drive Shaft5790
Maintenance Standard for Center Support5791
Maintenance Standard for Transmission Mount5793
Maintenance Standard for Torque Flow Assembly5795
Maintenance Standard for Torque Converter5797
Maintenance Standard for Modulation Clutch5804
Maintenance Standard for Valve Assembly (For Main Relief and Torque Converter Relief)5806
Maintenance Standard for Torque Converter Regulator Valve5808
Maintenance Standard for Transmission5810
Maintenance Standard for Transmission Control Valve5818
Maintenance Standard for F, R, 1st, 2nd, 3rd Clutch ECMV5819
Maintenance Standard for Modulation Clutch ECMV5821
Maintenance Standard for Transmission Lubrication Relief Valve5823
Maintenance Standard for Front Axle5824
Maintenance Standard for Rear Axle5826
Maintenance Standard for Front Differential5828
Maintenance Standard for Rear Differential5832
Maintenance Standard for Final Drive5836
Steering System5838
Maintenance Standard for Steering Pump5838
Maintenance Standard for Steering Cylinder5841
Brake System5843
Maintenance Standard for Brake5843
Maintenance Standard for Parking Brake5845
Maintenance Standard for Parking Brake Circuit Check Valve5847
Undercarriage and Frame5848
Maintenance Standard for Frame, Axle Mount and Center Hinge Pin5848
Hydraulic System5855
Maintenance Standard for Hydraulic Tank5855
Maintenance Standard for Work Equipment Pump5857
Maintenance Standard for Control Valve5860
Work Equipment5873
Maintenance Standard for Work Equipment Linkage5873
Maintenance Standard for Bucket5877
Maintenance Standard for Lift Cylinder5878
Maintenance Standard for Bucket Cylinder5879
CAB Related Parts5880
Maintenance Standard for CAB Mount5880
80 Others5881
Table of Contents5882
Precautions Before Work5884
Air Conditioner System5885
Precautions for Refrigerant5885
Air Conditioner Component5886
Specifications of Air Conditioner5888
Structure and Function of Refrigeration Cycle5889
Outline of Refrigeration Cycle5890
Component Parts of Air Conditioner System5892
Air Conditioner Unit5892
Component Parts of Air Conditioner Unit5895
Function of Evaporator5895
Function of Heater Core5895
Function of Evaporator Temperature Sensor5895
Function of Servomotor5895
Structure of Expansion Valve5896
Function of Expansion Valve5896
Operation of Expansion Valve5896
Function of Triple Pressure Switch5897
Air Conditioner Controller5899
Structure of Air Conditioner Controller5899
Compressor5900
Structure of Compressor5900
Specifications of Compressor5900
Function of Compressor5900
Operation of Compressor5901
Condenser5902
Structure of Condenser5902
Specifications of Condenser5902
Function of Condenser5902
Receiver Drier5904
Structure of Receiver Dryer5904
Specifications of Receiver Dryer5904
Function of Receiver Dryer5904
Air Conditioner Related Sensors5905
Structure of Sunlight Sensor5905
Function of Sunlight Sensor5905
Structure of Outside Temperature Sensor5905
Function of Outside Air Temperature Sensor5905
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner5906
Circuit Diagram and Configuration of Connector Pins of Air Conditioner5908
System Diagram of Air Conditioner5910
Input and Output Signals of Air Conditioner Controller5911
Function of Air Conditioner Controller5912
Locations of Air Conditioner Parts and Layout of Connectors5913
Examine Air Leakage (Duct)5917
How to Examine Air Leakage (Duct)5917
Examine Air Conditioner with Self-Diagnosis Function5919
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor5920
Examine Vent (Mode) Changeover5921
How to Examine Vent (Mode) Changeover5921
Examine Fresh/Recirc Air Changeover5922
How to Examine Fresh/Recirc Air Changeover5922
Examine Sunlight Sensor5923
How to Examine Sunlight Sensor5923
Examine Refrigerant (Triple) Pressure Switch5924
How to Examine Refrigerant (Triple) Pressure Switch5924
Examine Relay5926
How to Examine Relay5926
Air Conditioner Troubleshooting Chart 15927
Air Conditioner Troubleshooting Chart 25929
Information Shown in Troubleshooting5932
Troubleshooting by Failure Code (Display of Code)5935
Failure Code [879AKA]5935
Failure Code [879AKB]5936
Failure Code [879BKA]5937
Failure Code [879BKB]5940
Failure Code [879CKA]5943
Failure Code [879CKB]5944
Failure Code [879DKZ]5945
Failure Code [879EMC]5949
Failure Code [879FMC]5950
Failure Code [879GKX]5951
Troubleshooting of Air Conditioner System (A-Mode)5954
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)5954
Troubleshooting for Condenser5959
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)5966
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)5971
Troubleshooting for Fresh/Recirc Air Changeover5975
Troubleshooting by Gauge Pressure5978
Connect Service Tool5982
How to Connect Service Tool5982
Precautions for Disconnection and Connection of Air Conditioner Piping5983
Handle Compressor Oil5984
KomVision System5986
Structure and Operation of KomVision System5986
Precautions for KomVision System5986
Layout Drawing of KomVision System5987
Component Parts of KomVision System5993
Examine and Adjust KomVision System6006
Set and Operate KomVision Monitor6006
Camera Calibration6026
5 Camera Calibration6027
1 Camera Calibration6052
Adjust Radar (For Machine with Radar)6059
How to Set Default Radar Setting6059
How to Adjust Radar6061
Troubleshooting for KomVision System6066
Related Information to Troubleshooting6066
Troubleshooting by Failure Code (Display of Code)6084
Troubleshooting of Electrical System (E-Mode)6263
90 Circuit Diagrams6291
Table of Contents6292
How to Read the Codes for Electric Cable6293
Hydraulic Circuit Diagram6297
Symbols Used in Hydraulic Circuit Diagram6297
Hydraulic Circuit Diagram for Work Equipment6301
Power Train Hydraulic Circuit Diagram6303
Hydraulic Circuit Diagram for Work Equipment (Combination of Forward 1st Travel, Boom RAISE and Bucket TILT Operation (1/2)6305
Hydraulic Circuit Diagram for Power Train (Combination of Forward 1st Travel, Boom RAISE and Bucket TILT Operation 2/2)6307
Hydraulic Circuit Diagram for Work Equipment (Combination of Boom LOWER, Reverse 2nd Travel, Steer Left, and Left Brake Operation 1/2)6309
Hydraulic Circuit Diagram for Power Train (Combination of Boom LOWER, Reverse 2nd Travel, Steer Left, and Left Brake Operation 2/2)6311
Electrical Circuit Diagram6313
Symbols Used in Electric Circuit Diagram6313
Electrical Circuit Diagram of Machine (1/8)6317
Electrical Circuit Diagram of Machine (2/8)6319
Electrical Circuit Diagram of Machine (3/8)6321
Electrical Circuit Diagram of Machine (4/8)6323
Electrical Circuit Diagram of Machine (5/8)6325
Electrical Circuit Diagram of Machine (6/8)6327
Electrical Circuit Diagram of Machine (7/8)6329
Electrical Circuit Diagram of Machine (8/8)6331
Electrical Circuit Diagram of Floor (1/8)6333
Electrical Circuit Diagram of Floor (2/8)6335
Electrical Circuit Diagram of Floor (3/8)6337
Electrical Circuit Diagram of Floor (4/8)6339
Electrical Circuit Diagram of Floor (5/8)6341
Electrical Circuit Diagram of Floor (6/8)6343
Electrical Circuit Diagram of Floor (7/8)6345
Electrical Circuit Diagram of Floor (8/8)6347
Electrical Circuit Diagram of Engine (1/2)6349
Electrical Circuit Diagram of Engine (2/2)6351
Index6353
S.M 30/12/24
