Komatsu WHEEL LOADER WA800-8E0 WA900-8E0 Shop Manual SEN06751-14 PDF
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Komatsu WHEEL LOADER WA800-8E0 WA900-8E0 Shop Manual SEN06751-14 PDF DOWNLOAD
SERIAL NUMBERS WA800-83001
WA900-93001 and up
Description
Komatsu WHEEL LOADER WA800-8E0 WA900-8E0 Shop Manual SEN06751-14 PDF DOWNLOAD
FILE DETAILS:
Komatsu WHEEL LOADER WA800-8E0 WA900-8E0 Shop Manual SEN06751-14 PDF DOWNLOAD
Language : English
Pages :6396
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WHEEL LOADER WA800-8E0 WA900-8E0 Shop Manual SEN06751-14 PDF DOWNLOAD
SERIAL NUMBERS WA800-83001
WA900-93001 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 WA800-8E0 WA900-8E0 Shop Manual SEN06751-14 PDF DOWNLOAD
SERIAL NUMBERS WA800-83001
WA900-93001 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 WA800-8E0 89
Specification Drawing WA900-8E0 91
Specifications 93
Specifications WA800-8E0 93
Specifications WA900-8E0 98
Weight Table 103
Weight Table WA800-8E0 103
Weight Table WA900-8E0 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
NOx Control System 116
Function of NOx Control System 116
Inducement Strategy 116
Inducement Strategy When Abnormality is Found in the EGR System (EU Specification) 116
Function of Temporary Restoration from Inducement (EU Specification) 117
Inducement Strategy for Abnormality Recurrence (EU Specification) 118
Boot-up System 119
Layout Drawing of Boot-up System 119
Pre-lubrication System 121
Pre-lubrication System Diagram 121
Function of Pre-lubrication System 121
Operation of Pre-lubrication System 123
System Operating Lamp System 125
System Diagram of System Operating Lamp System 125
Function of Operation Lamp System 125
Operation of System Operating Lamp System 125
Battery Disconnect Switch 126
Function of Battery Disconnect Switch 126
Operation of Battery Disconnect Switch 126
Starting Motor Disconnect Switch 127
Function of Starting Motor Disconnect Switch 127
Preheating System 128
System Diagram of Preheating System 128
Function of Automatic Preheating System 128
Operation of Automatic Preheating System 129
Function of Manual Preheating System 129
Operation of Manual Preheating System 129
Engine Shutdown Secondary Switch 130
Function of Engine Shutdown Secondary Switch 130
Operation of Engine Shutdown Secondary Switch 130
Emergency Engine Stop Switch 131
Function of Emergency Engine Stop Switch 131
Operation of Emergency Engine Stop Switch 131
External Power Supply Engine Preheater 132
Function of External Power Supply Engine Preheater 132
Engine System 133
Layout Drawing of Engine System 133
Engine Control System 135
System Diagram of Engine Control 135
Operation of Engine Control System 136
Engine Output Torque Control Function 137
Engine Automatic Warm-up Function 137
Engine Power Mode Selector System 138
Engine Power Mode Selector System Diagram 138
Function of Engine Power Mode Selector System 138
Operation of Engine Power Mode Selector System 138
Automatic Idle Stop System 139
Function of Automatic Idle Stop System 139
RPM Set 140
Function of RPM Set 140
Component Parts of Engine System 142
Damper 142
VGT 144
EGR System 148
EGR Valve 152
EGR Cooler 154
KCCV System 155
KCCV 158
KDPF 160
Cooling System 164
Layout Drawing of Cooling System 164
Specifications of Cooling System 166
Cooling Fan Control System 167
System Diagram of Cooling Fan Control System 167
Function of Cooling Fan Control System 168
Component Parts of Cooling System 171
Cooling Fan Pump 171
Cooling Pump 179
Cooling Fan Motor 180
Control System 186
Layout Drawing of Control System 186
Machine Monitor System 188
System Diagram of Machine Monitor System 188
Function of Machine Monitor System 189
Rearview Monitor System 190
System Diagram of Rearview Monitor System 190
Function of Rearview Monitor System 190
KOMTRAX Plus System 191
System Diagram of KOMTRAX Plus System 191
Function of KOMTRAX Plus System 191
Load Meter System 193
System Diagram of Load Meter 193
Function of Load Meter System 193
Machine Lock-out System 199
Layout Drawing of Machine Lock-out System 199
Function of Machine Lock-out System 199
Operation of Machine Lock-out System 199
Component Parts of Control System 201
Machine Monitor 201
Switch Panel 220
Rearview Monitor 221
Rearview Camera 223
KOMTRAX Terminal 224
KOMTRAX Plus Controller 226
Wireless LAN Unit 231
Transmission Controller 232
Work Equipment Controller 236
Monitor Controller 240
CAN Terminating Resistor 245
Engine Controller 246
Accelerator Pedal 259
Fuel Feed Pump 262
Fuel Feed Pump Switch 263
Hydraulic System 264
Layout Drawing of Hydraulic System 264
CLSS 265
Structure of CLSS 265
Function of CLSS 266
Work Equipment Pump Control System 268
Swash Plate Control Function of Work Equipment Pump 268
Pickup Assistance Control Function of Work Equipment Pump When Engine Speed is Low 268
Steering Pump Control System 270
Swash Plate Control Function of Steering Pump 270
Pickup Assistance Control Function of Steering Pump When Engine Speed is Low 270
Component Parts of Hydraulic System 271
Hydraulic Tank 271
Work Equipment Pump 275
Steering Pump 294
Pilot Brake Charge Pump 310
Pump Assembly (to Lubricate Transmission and Torque Converter) 311
Accumulator Charge Valve 312
Control Valve 317
Power Train System 352
Layout Drawing of Power Train System 352
Operation of Power Train System 355
Transmission Control System 356
Transmission Control System Diagram 356
Transmission Gear Shift Control System 358
Electric Modulation Function System Diagram 358
Electric Modulation Function 359
Gear Shift Display Function 359
Automatic Gear Shift Function 359
Shift Hold Function 360
Kickdown Function 360
Automatic Kickdown Function 361
Hunting Prevention Function 361
Transmission Initial Learning and ECMV Current Adjustment Function 361
Shift Point Changing Function 361
3rd Gear Speed Limitation Function 362
Transmission Protection Function 363
Protection Function When Travel Direction is Changed 363
Shift Down Protection Function 363
Engine Overrun Prevention Function 364
Neutralizer Function 364
Modulation Clutch Control Function 364
Tire Slip Control System 367
Tire Slip Control System Diagram 367
Function of Tire Slip Control System 367
Operation of Tire Slip Control System 367
Component Parts of Power Train System 369
Drive Shaft 369
Center Support 371
Torque Flow Assembly 372
Torque Converter 373
Valve Assembly (For Main Relief and Torque Converter Relief) 381
Torque Converter Regulator Valve 384
Transmission 386
Transmission Control Valve 404
Modulation Clutch ECMV 407
F, R, 1st, 2nd, 3rd Clutch ECMV 410
Transmission Lubrication Relief Valve 415
Axle 416
Differential 419
Final Drive 422
AJSS Knob 424
Shift Hold Switch 425
Kickdown Switch 426
Work Equipment System 427
Layout Drawing of Work Equipment System 427
Work Equipment System Diagram 429
Work Equipment Control System 431
Work Equipment Speed Pattern Control Function by Work Equipment Lever Stroke 431
Work Equipment Lever Detent Position and Work Equipment Startup Current Control Function 432
Work Equipment Lever Operating Function System Diagram 433
Work Equipment Lever Operation Function 433
Bucket Priority Control Function 434
Boom Stop Modulation Function 434
Work Equipment Shock Reduction Function 435
Tilt Shock Reduction Function 435
Dump Shock Reduction Function 436
Work Equipment Neutral Lock System 438
Work Equipment Neutral Lock System Diagram 438
Function of Work Equipment Neutral Lock System 438
Remote Positioner System 440
Remote Bucket Positioner System Diagram 440
Function of Remote Bucket Positioner System 440
Remote Boom Positioner System Diagram 441
Function of Remote Boom Positioner System 441
Bucket Positioner and Boom Positioner 445
Structure of Bucket Positioner and Boom Positioner 445
Auto-Digging System 446
Auto-Digging System Diagram 446
Function of Auto-Digging System 446
Semi-Auto Approach System 448
Semi-Auto Approach System Diagram 448
Function of Semi-Auto Approach System 448
Semi-Auto Dump System 449
Semi-Auto Dump System Diagram 449
Function of Semi-Auto Dump System 449
ECSS 451
ECSS Diagram 451
Function of ECSS 451
Operation of ECSS 451
Wall Digging Prevention Control System 453
Wall Digging Prevention Control System Diagram 453
Function of Wall Digging Prevention Control System 453
Component Parts of Work Equipment System 455
Solenoid Valve (Work Equipment Lock) 455
Pilot Circuit Accumulator 456
ECSS Circuit Accumulator 457
Work Equipment Electric Lever 458
Steering System 461
Layout Drawing of Steering System 461
Secondary Steering System 462
Secondary Steering System Diagram 462
Function of Secondary Steering System 462
AJSS 463
Layout Drawing of AJSS 463
AJSS System Diagram 464
Function of AJSS 465
Neutralizer Function of AJSS 466
AJSS Neutral Interlock Function 466
AJSS Speed Sensing Steering Function 467
AJSS Turn Signal Pilot Lamp Control Function 469
Steering Lock System 470
Steering Lock System Diagram 470
Function of Steering Lock System 470
Component Parts of Steering System 471
AJSS EPC Valve 471
Solenoid Valve (For Steering Lock) 472
Steering Lock Valve 473
Rotary Valve 474
Steering Valve 478
Diverter Valve 492
Secondary Steering Relief Valve 495
Secondary Steering Pump 497
Lubrication for Hinge Pin and Steering 498
Brake System 499
Layout Drawing of Brake System 499
Parking Brake Control System 502
System Diagram of Parking Brake Control System 502
Operation of Parking Brake Control System 502
Component Parts of Brake System 504
Solenoid Valve (Parking Brake) 504
Parking Brake Emergency Release Valve 506
Brake Circuit Accumulator 507
Brake Valve 508
Slack Adjuster 514
Brake 517
Parking Brake 519
Parking Brake Circuit Check Valve 522
Pump Assembly (For Brake Cooling) 523
Auto-Greasing System 524
Layout Drawing of Auto-Greasing System 524
Auto-Greasing System Diagram 527
Specifications of Auto-Greasing System 528
Function of Auto-Greasing System 529
Auto-Greasing System 530
Auto-Greasing Pump 530
Auto-Greasing Injector 532
Lifting System 535
Power Ladder System 535
Layout Drawing of Power Ladder System 535
Power Ladder System Diagram 536
Function of Power Ladder System 537
Operation of Power Ladder System 537
Power Ladder System 539
Power Ladder Pump 539
Power Ladder Relief Valve 541
Solenoid Valve (Power Ladder Shock Reduction) 542
Solenoid Valve (Power Ladder Raise and Lower Switch) 543
Undercarriage and Frame 544
Frame, Axle Mount and Hinge Pin 544
Structure of Frame, Axle Mount and Hinge Pin 544
Function of Frame, Axle Mount and Hinge Pin 546
Structure of Lubrication System for Undercarriage 547
Service Center 548
Service Center 548
Service Center System Diagram 549
Function of Service Center 549
Grease Refill Automatic Stop System 550
Tires 552
Structure of Radial Tire 552
Function of Radial Tire 552
Work Equipment 553
Structure of Work Equipment 553
Structure of Bucket 554
Structure of Lubrication System for Work Equipment 555
CAB Related Parts 557
ROPS 557
Structure of ROPS 557
Function of ROPS 557
CAB 558
Structure of CAB 558
CAB Mount 559
Structure of CAB Mount 559
Function of CAB Mount 559
20 Standard Value Table 561
Table of Contents 562
Standard Value Table for Engine 563
Standard Value Table for Engine: WA800-8E0 563
Standard Value Table for Engine: WA900-8E0 568
Standard Value Table for Machine 573
Standard Value Table for Machine: WA800-8E0 573
Standard Value Table for Machine: WA900-8E0 588
Machine Posture and Procedures to Measure Performance 602
30 Testing and Adjusting 605
Table of Contents 606
Precautions Before Work 610
Related Information on Testing and Adjusting 611
Tools for Testing and Adjusting 611
Sketch of Tools for Testing and Adjusting 621
Engine and Cooling System 622
Examine Engine Speed 622
How to Examine Engine Speed 622
Examine Boost Pressure 626
How to Examine Boost Pressure on Machine Monitor 626
How to Examine Boost Pressure by Testing Tool 627
Examine Exhaust Gas Temperature 630
How to Examine Exhaust Gas Temperature 630
Examine Exhaust Gas Color 632
How to Examine Exhaust Gas Color with the Handy Smoke Checker 632
How to Examine Exhaust Gas Color with Smoke Meter 635
Examine Mass Air Flow and Temperature Sensor 640
How to Examine Mass Air Flow and Temperature Sensor 640
Examine and Adjust Valve Clearance 645
How to Examine Valve Clearance 645
How to Adjust Valve Clearance 647
Examine Compression Pressure 648
How to Examine Compression Pressure 648
Examine Blowby Pressure 652
How to Examine Blowby Pressure 652
Examine Engine Oil Pressure 657
How to Examine Engine Oil Pressure on Machine Monitor 657
How to Examine Engine Oil Pressure by Testing Tool 658
Examine EGR Valve and VGT Oil Pressure 660
How to Examine EGR Valve and VGT Oil Pressure 660
Examine Fuel Pressure 662
How to Examine Fuel Pressure 662
Examine Fuel Return Rate and Leakage 664
How to Examine Fuel Return Rate and Leakage 665
Bleed Air from Fuel System 672
How to Bleed Air from Fuel System 672
Examine Fuel Circuit for Leakage 674
How to Examine Fuel System for Leakage 674
Examine Low Pressure Circuit Devices 675
How to Examine Low Pressure Circuit Devices 675
Handle Cylinder Cut-out Mode Operation 683
Handle No-Injection Cranking Operation 684
Examine KDPF and Muffler Stack for Looseness and Damage 685
How to Examine KDPF and Muffler Stack for Looseness and Damage 685
Examine Installation of Cylinder Head Cover and Manifolds 686
How to Examine Installed Condition of Cylinder Head covers and Manifolds 686
Examine Engine Piping for Damage and Looseness 687
How to Examine Engine Piping for Damage and Looseness 687
Clean Fuel Doser 688
How to Clean Fuel Doser 688
Write Injector Compensation Value to Engine Controller 691
How to Write Injector Compensation Value 691
Write Correction for Ash in Soot Accumulation to Engine Controller 698
How to Write Correction for Ash in Soot Accumulation to Engine Controller 698
Examine and Adjust Alternator Belt 699
How to Examine Alternator Belt 699
How to Adjust Alternator Belt Tension 700
Examine and Adjust Air Conditioner Compressor Belt 701
How to Examine Air Conditioner Compressor Belt 701
How to Adjust Air Conditioner Compressor Belt Tension 702
Bleed Air from Engine Coolant Circuit 703
How to Bleed Air from Engine Coolant Circuit 703
Power Train 705
Examine and Adjust Power Train Oil Pressure 705
How to Examine Power Train Oil Pressure 707
How to Adjust Power Train Oil Pressure 722
Examine Modulation Clutch Output Speed Sensor 724
How to Examine Modulation Clutch Output Speed Sensor 724
Examine Transmission Output Speed Sensor 725
How to Examine Transmission Output Speed Sensor 725
Adjust Wheel Speed Sensor 727
How to Adjust Wheel Speed Sensor 727
Flush Torque Converter and Transmission Hydraulic Circuit 728
How to Flush Torque Converter and Transmission Hydraulic Circuit 728
Move Disabled Machine Due to Transmission Valve Failure 731
How to Move Disabled Machine Due to Transmission Valve Failure 731
Examine Drive Shaft for Looseness, Backlash, and Damage 734
How to Examine Drive Shaft for Looseness, Backlash, and Damage 734
Steering System 735
Examine and Adjust Steering Circuit Oil Pressure 735
How to Examine Steering Circuit Oil Pressure 735
How to Adjust Steering Circuit Oil Pressure 738
Brake System 740
Release Remained Pressure in Brake Accumulator Circuit 740
How to Release Remained Pressure in Brake Accumulator Circuit 740
Examine Wheel Brake Oil Pressure 741
How to Examine Wheel Brake Oil Pressure 741
Examine and Adjust Brake Accumulator Charge Pressure 743
How to Examine Brake Accumulator Charge Pressure 743
How to Adjust Brake Accumulator Charge Pressure 745
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas 747
How to Examine Accumulator Nitrogen Gas Pressure for Brake 747
How to Charge Accumulator Nitrogen Gas for Brake 751
How to Release Nitrogen Gas When You Discard Accumulator 756
Examine Brake Performance 757
How to Examine Brake Performance 757
Examine Brake Pedal 758
How to Examine Brake Pedal 758
Adjust Right Brake Pedal Switch 760
How to Adjust Right Brake Pedal Switch 760
Bleed Air from Brake Circuit 762
How to Bleed Air from Brake Circuit 762
Examine Wear of Wheel Brake Disc 764
How to Examine Wear of Wheel Brake Disc 764
Examine Parking Brake Oil Pressure 766
How to Examine Parking Brake Oil Pressure 766
Examine Parking Brake Performance 768
How to Examine Parking Brake Performance 768
Release Parking Brake Manually 769
How to Release Parking Brake Manually 769
Examine Wear Volume of Parking Brake Disc 771
How to Examine Wear Quantity of Parking Brake Disc 771
Hydraulic System 773
Release Remained Pressure from Work Equipment Circuit 773
How to Release Remained Pressure from Work Equipment Circuit 773
Examine and Adjust Work Equipment Oil Pressure 775
How to Examine Work Equipment Oil Pressure 775
How to Adjust Work Equipment Oil Pressure 780
Examine and Adjust Work Equipment EPC Oil Pressure 782
How to Examine Work Equipment EPC Oil Pressure 782
How to Adjust Work Equipment EPC Oil Pressure 784
Bleed Air from Hydraulic System 785
How to Bleed Air from Hydraulic System 785
Examine Cooling Fan Speed 791
How to Examine Cooling Fan Speed 791
Examine Cooling Fan Circuit Oil Pressure 792
How to Examine Cooling Fan Circuit Oil Pressure 792
How to Examine Cooling Fan Reverse Solenoid Outlet Pressure 793
Bleed Air from Cooling Fan Circuit 796
How to Bleed Air from Cooling Pump 796
How to Bleed Air from Fan Motor Circuit 797
Examine ECSS Accumulator Charge Pressure 798
How to Examine ECSS Accumulator Charge Pressure 798
Examine ECSS Accumulator Nitrogen Gas Pressure and Charge Accumulator with Nitrogen Gas 800
How to Examine ECSS Accumulator Nitrogen Gas Pressure 800
How to Charge ECSS Accumulator with Nitrogen Gas 803
Work Equipment 808
Examine and Adjust Bucket Potentiometer Lever 808
How to Examine Bucket Potentiometer Lever 808
How to Adjust Bucket Potentiometer Lever 808
Examine and Adjust Boom Potentiometer Lever 810
How to Examine Boom Potentiometer Lever 810
How to Adjust Boom Potentiometer Lever 810
Examine Hydraulic Drift of Work Equipment 811
How to Examine Hydraulic Drift of Work Equipment 811
Examine Work Equipment Speed 813
How to Examine Work Equipment Speed 813
Device to Get on or Off Machine 814
Adjust Deceleration of Power Ladder 814
How to Adjust Deceleration of Power Ladder 815
CAB Related Parts 817
Examine Work Equipment Control Lever 817
How to Examine Work Equipment Control Lever 817
Examine AJSS Lever 819
How to Examine Operating Time of AJSS Lever 819
How to Examine Operating Force of AJSS Lever 820
How to Examine Operating Force of Directional Switch 821
How to Examine Operating Force of Gear Speed Switch 821
Examine and Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor 822
How to Examine AJSS Lever Angle Sensor and AJSS Frame Angle Sensor 822
How to Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor 822
Examine and Adjust Steering Stopper Bolt 824
How to Examine Steering Stopper Bolt 824
How to Adjust Steering Stopper Bolt 824
Adjust Play of Operator Seat 825
How to Adjust Play of Operator Seat 825
Adjust Door Lock Link 826
How to Adjust Door Lock Link 826
Electrical System 829
Set and Adjust Each Equipment 829
Set and Operate Machine Monitor 834
Operator Mode 838
Function to Show Operator Identification Input Screen 838
Examine Function by LCD (Liquid Crystal Display) 839
Examine Function of Service Meter and Odometer 840
How to Set Usage Limitation and Change Maintenance Password 840
Service Mode 844
How to Operate Service Mode 844
How to See Pre-defined Monitoring Information 846
How to Examine Monitoring Information 852
Abnormality Record Menu 867
How to See Maintenance Record 871
Maintenance Mode Setting 873
How to Set Phone Number Entry 879
Default Setting Menu 880
Testing Menu 898
Adjustment Menu 911
No-Injection Cranking Operation 948
KOMTRAX Settings Menu 951
How to Show Service Message 953
How to Operate Snap Shot 954
How to Start Up KOMTRAX Terminal 957
How to Stop Use of KOMTRAX Terminal 961
Default Setting of KOMTRAX Plus Controller 963
Default Setting of KOMTRAX Plus Controller 963
Default Setting of Wireless LAN Modem 966
Default Setting of Wireless LAN Modem 966
How to Examine Wireless LAN Modem Communication 967
Download Data from KOMTRAX Plus Controller 969
How to Download Data from KOMTRAX Plus Controller 969
How to Download Data from Service Connector 969
How to Download Data from Wireless LAN 970
Adjust After Replacement of KOMTRAX Plus Controller 972
How to Adjust After Replacement of KOMTRAX Plus Controller 972
Adjust After Replacement of Wireless LAN Modem 975
How to Adjust After Replacement of Wireless LAN Modem 975
Adjust Rearview Camera Angle 978
How to Adjust Rearview Camera Angle 978
Set Region of Bluetooth(R) Compatible Radio 979
How to Set Region of Bluetooth(R) Compatible Radio 979
Handle Voltage Circuit of Engine Controller 981
Handle Battery Disconnect Switch 982
Examine Diodes 983
How to Examine Diodes by Digital Tester 983
How to Examine Diodes by Analog Tester 983
Pm Clinic 984
Pm Clinic Service 984
Pm Clinic Check Sheet: WA800-8E0 987
Pm Clinic Check Sheet: WA900-8E0 999
Perform Quick Pm1011
How to Perform Quick Pm1011
40 Troubleshooting1015
Table of Contents1016
Precautions Before Work1032
Related Information for Troubleshooting1033
General Troubleshooting Points1033
Troubleshooting Points for Aftertreatment System1034
Sequence of Events in Troubleshooting1043
Checks Before Troubleshooting1045
Inspection Procedure Before Troubleshooting1047
Walk-Around Check1047
Test in Accordance with Testing Procedure1049
Examine Fuel Level and Type1049
Examine for Impure Ingredient in Fuel1049
Replace Fuel Prefilter Cartridge1050
Replace Fuel Main Filter Cartridge1051
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type1053
Examine Coolant Level (Reservoir Tank)1054
Examine, Clean and Replace Air Cleaner1055
Examine Hydraulic Oil Level1060
Examine Hydraulic Oil Filter or Hydraulic Oil Strainer1061
Examine Oil Level in Transmission Case1062
Examine Oil Level in Axle Case1064
Bleed Air from Fuel System1066
Bleed Air from Hydraulic System1066
How to Examine Electric Equipment1066
Preparation for Troubleshooting of Electrical System1073
How to Connect Adapter for Troubleshooting Work Equipment Controller1073
How to Connect Adapter for Troubleshooting Engine Controller1074
How to Connect Adapter to Troubleshoot Transmission Controller1075
How to Connect Adapter to Troubleshoot Monitor Controller1076
How to Connect Adapter to Troubleshoot KOMTRAX Terminal1079
How to Connect Adapter to Troubleshoot KOMTRAX Plus Controller1079
How to Connect Adapter to Troubleshoot KomVision Controller1080
How to Connect Connectors for Engine Related Parts1080
How to Disconnect KomVision Radar Connector1084
Procedure for Troubleshooting1086
Symptom and Troubleshooting Numbers1089
Information Shown in Troubleshooting1101
Connectors List1104
Connector Layout1128
Connector Contact Connection Table1144
T-Branch Box and T-Branch Adapter Table1191
Fuse Location Table1197
Precautions When You Clean and Replace KDPF (KCSF and KDOC)1201
Prepare Troubleshoot Machine Monitor1205
Procedure to Make Harness Checker on Machine Monitor LCD Unit1207
Prepare of Short Circuit Electrical Connector (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135])1212
Failure Code Table1214
Troubleshooting by Failure Code (Display of Code)1244
Failure Code [1500L0]1244
Failure Code [15B0NX]1246
Failure Code [15SAL1]1249
Failure Code [15SALH]1252
Failure Code [15SBL1]1255
Failure Code [15SBLH]1258
Failure Code [15SEL1]1261
Failure Code [15SELH]1264
Failure Code [15SFL1]1267
Failure Code [15SFLH]1270
Failure Code [15SGL1]1273
Failure Code [15SGLH]1276
Failure Code [15W0NT]1279
Failure Code [2F00MA]1281
Failure Code [2F00MB]1287
Failure Code [2G42ZG]1292
Failure Code [2G43ZG]1295
Failure Code [879AKA]1298
Failure Code [879AKB]1299
Failure Code [879BKA]1300
Failure Code [879BKB]1303
Failure Code [879CKA]1306
Failure Code [879CKB]1307
Failure Code [879DKZ]1308
Failure Code [879EMC]1312
Failure Code [879FMC]1313
Failure Code [879GKX]1314
Failure Code [989A00]1317
Failure Code [989L00]1318
Failure Code [989M00]1319
Failure Code [989N00]1320
Failure Code [A1U0N3]1321
Failure Code [A1U0N4]1325
Failure Code [AA10NX]1329
Failure Code [AB00KE]1332
Failure Code [AB00KY]1335
Failure Code [AQ10N3]1337
Failure Code [AS00R2]1340
Failure Code [AS00R3]1342
Failure Code [AS00R4]1344
Failure Code [AS00R6]1346
Failure Code [B@BAZG]1347
Failure Code [B@BAZK]1350
Failure Code [B@BCNS]1353
Failure Code [B@BCZK]1356
Failure Code [B@C6NS]1359
Failure Code [B@C7NS]1362
Failure Code [B@CENS]1365
Failure Code [B@GAZK]1368
Failure Code [B@HANS]1371
Failure Code [CA115]1374
Failure Code [CA122]1379
Failure Code [CA123]1382
Failure Code [CA131]1386
Failure Code [CA132]1389
Failure Code [CA135]1392
Failure Code [CA141]1395
Failure Code [CA144]1398
Failure Code [CA145]1401
Failure Code [CA153]1404
Failure Code [CA154]1408
Failure Code [CA187]1412
Failure Code [CA212]1416
Failure Code [CA213]1419
Failure Code [CA221]1422
Failure Code [CA222]1425
Failure Code [CA227]1429
Failure Code [CA234]1432
Failure Code [CA238]1434
Failure Code [CA239]1437
Failure Code [CA271]1440
Failure Code [CA272]1443
Failure Code [CA273]1445
Failure Code [CA274]1448
Failure Code [CA322]1450
Failure Code [CA323]1453
Failure Code [CA324]1456
Failure Code [CA325]1459
Failure Code [CA331]1462
Failure Code [CA332]1465
Failure Code [CA343]1468
Failure Code [CA351]1476
Failure Code [CA352]1484
Failure Code [CA356]1488
Failure Code [CA357]1492
Failure Code [CA386]1496
Failure Code [CA431]1500
Failure Code [CA432]1504
Failure Code [CA441]1509
Failure Code [CA442]1513
Failure Code [CA449]1517
Failure Code [CA451]1520
Failure Code [CA452]1523
Failure Code [CA515]1526
Failure Code [CA516]1528
Failure Code [CA553]1531
Failure Code [CA555]1534
Failure Code [CA556]1537
Failure Code [CA559]1540
Failure Code [CA595]1546
Failure Code [CA687]1549
Failure Code [CA689]1553
Failure Code [CA691]1558
Failure Code [CA692]1561
Failure Code [CA697]1564
Failure Code [CA698]1566
Failure Code [CA731]1568
Failure Code [CA778]1576
Failure Code [CA1117]1581
Failure Code [CA1135]1586
Failure Code [CA1257]1597
Failure Code [CA1664]1599
Loaded Diagnostics Operation to Clear Failure Code1601
Failure Code [CA1691]1603
Failure Code [CA1695]1608
Failure Code [CA1696]1611
Failure Code [CA1843]1614
Failure Code [CA1844]1617
Failure Code [CA1879]1620
Failure Code [CA1881]1624
Failure Code [CA1883]1628
Loaded Diagnostics Operation to Clear Failure Code1631
Failure Code [CA1921]1633
Failure Code [CA1922]1641
Failure Code [CA1923]1648
Failure Code [CA1924]1651
Diagram Related to Fuel Doser1654
Failure Code [CA1925]1656
Diagram Related to Fuel Doser1658
Failure Code [CA1927]1660
Failure Code [CA1928]1663
Failure Code [CA1942]1666
Failure Code [CA1963]1669
Diagram Related to Fuel Doser1675
Failure Code [CA1977]1677
Loaded Diagnostics Operation to Clear Failure Code1680
Failure Code [CA1993]1681
Loaded Diagnostics Operation to Clear Failure Code1683
Failure Code [CA2185]1685
Failure Code [CA2186]1688
Failure Code [CA2249]1691
Failure Code [CA2265]1698
Failure Code [CA2266]1701
Failure Code [CA2271]1704
Failure Code [CA2272]1707
Failure Code [CA2349]1711
Failure Code [CA2353]1715
Failure Code [CA2357]1718
Failure Code [CA2381]1723
Failure Code [CA2382]1726
Failure Code [CA2383]1730
Failure Code [CA2386]1734
Failure Code [CA2387]1736
Failure Code [CA2555]1746
Failure Code [CA2556]1749
Failure Code [CA2637]1752
Failure Code [CA2639]1759
Failure Code [CA2732]1767
Failure Code [CA2733]1770
Failure Code [CA2741]1773
Diagram Related to Fuel Doser1774
Failure Code [CA2765]1776
Failure Code [CA2777]1778
Failure Code [CA2878]1781
Diagram Related to Fuel Doser1785
Failure Code [CA2881]1787
Loaded Diagnostics Operation to Clear Failure Code1791
Failure Code [CA3133]1794
Failure Code [CA3134]1797
Failure Code [CA3135]1801
Loaded Diagnostics Operation to Clear Failure Code1804
Failure Code [CA3167]1806
How to Reset Fuel Doser Information1809
Failure Code [CA3251]1812
Loaded Diagnostics Operation to Clear Failure Code1819
Failure Code [CA3253]1820
Loaded Diagnostics Operation to Clear Failure Code1828
Failure Code [CA3254]1830
Loaded Diagnostics Operation to Clear Failure Code1837
Failure Code [CA3255]1839
Loaded Diagnostics Operation to Clear Failure Code1846
Failure Code [CA3256]1848
Loaded Diagnostics Operation to Clear Failure Code1855
Failure Code [CA3311]1857
Loaded Diagnostics Operation to Confirm Failure Correction1864
Failure Code [CA3312]1866
Loaded Diagnostics Operation to Confirm Failure Correction1873
Failure Code [CA3313]1875
Failure Code [CA3314]1878
Failure Code [CA3315]1881
Loaded Diagnostics Operation to Confirm Failure Correction1886
Failure Code [CA3316]1888
Failure Code [CA3317]1891
Failure Code [CA3318]1894
Loaded Diagnostics Operation to Confirm Failure Correction1899
Failure Code [CA3319]1901
Failure Code [CA3321]1904
Failure Code [CA3322]1907
Loaded Diagnostics Operation to Confirm Failure Correction1912
Failure Code [CA3419]1914
Failure Code [CA3421]1916
Failure Code [CA4151]1919
Failure Code [CA4158]1927
Failure Code [CA4161]1930
Failure Code [CA4162]1933
Failure Code [CA4163]1936
Loaded Diagnostics Operation to Confirm Failure Correction1938
Failure Code [CA4259]1939
Failure Code [CA4952]1942
Failure Code [CA5383]1945
Failure Code [CB115]1947
Failure Code [CB122]1952
Failure Code [CB123]1955
Failure Code [CB153]1959
Failure Code [CB154]1963
Failure Code [CB187]1967
Failure Code [CB227]1971
Failure Code [CB238]1974
Failure Code [CB239]1977
Failure Code [CB271]1980
Failure Code [CB272]1983
Failure Code [CB273]1985
Failure Code [CB274]1988
Failure Code [CB343]1990
Failure Code [CB351]1997
Failure Code [CB352]2005
Failure Code [CB356]2009
Failure Code [CB357]2013
Failure Code [CB386]2017
Failure Code [CB441]2020
Failure Code [CB442]2024
Failure Code [CB449]2028
Failure Code [CB451]2031
Failure Code [CB452]2034
Failure Code [CB515]2037
Failure Code [CB516]2039
Failure Code [CB553]2042
Failure Code [CB555]2045
Failure Code [CB556]2048
Failure Code [CB559]2051
Failure Code [CB595]2057
Failure Code [CB687]2060
Failure Code [CB689]2064
Failure Code [CB691]2069
Failure Code [CB692]2072
Failure Code [CB697]2075
Failure Code [CB698]2077
Failure Code [CB731]2079
Failure Code [CB778]2088
Failure Code [CB1117]2093
Failure Code [CB1257]2098
Failure Code [CB1548]2100
Failure Code [CB1549]2103
Failure Code [CB1551]2106
Failure Code [CB1552]2109
Failure Code [CB1553]2112
Failure Code [CB1622]2115
Failure Code [CB1664]2118
Loaded Diagnostics Operation to Clear Failure Code2121
Failure Code [CB1691]2122
Failure Code [CB1695]2127
Failure Code [CB1696]2130
Failure Code [CB1843]2133
Failure Code [CB1844]2136
Failure Code [CB1879]2139
Failure Code [CB1881]2143
Failure Code [CB1883]2147
Loaded Diagnostics Operation to Clear Failure Code2150
Failure Code [CB1921]2152
Failure Code [CB1922]2160
Failure Code [CB1923]2167
Failure Code [CB1924]2170
Diagram Related to Fuel Doser2173
Failure Code [CB1925]2175
Diagram Related to Fuel Doser2177
Failure Code [CB1927]2179
Failure Code [CB1928]2182
Failure Code [CB1942]2186
Failure Code [CB1963]2189
Diagram Related to Fuel Doser2195
Failure Code [CB1977]2197
Loaded Diagnostics Operation to Clear Failure Code2200
Failure Code [CB1993]2201
Loaded Diagnostics Operation to Clear Failure Code2203
Failure Code [CB2249]2205
Failure Code [CB2265]2211
Failure Code [CB2266]2214
Failure Code [CB2271]2217
Failure Code [CB2272]2220
Failure Code [CB2349]2224
Failure Code [CB2353]2228
Failure Code [CB2357]2231
Failure Code [CB2381]2236
Failure Code [CB2382]2239
Failure Code [CB2383]2243
Failure Code [CB2386]2247
Failure Code [CB2387]2249
Failure Code [CB2637]2259
Failure Code [CB2639]2266
Failure Code [CB2732]2275
Failure Code [CB2733]2278
Failure Code [CB2741]2281
Diagram Related to Fuel Doser2282
Failure Code [CB2765]2284
Failure Code [CB2777]2286
Failure Code [CB2878]2289
Diagram Related to Fuel Doser2293
Failure Code [CB2881]2295
Loaded Diagnostics Operation to Clear Failure Code2299
Failure Code [CB3133]2302
Failure Code [CB3134]2305
Failure Code [CB3135]2309
Loaded Diagnostics Operation to Clear Failure Code2312
Failure Code [CB3167]2314
How to Reset Fuel Doser Information2317
Failure Code [CB3251]2320
Loaded Diagnostics Operation to Clear Failure Code2327
Failure Code [CB3253]2328
Loaded Diagnostics Operation to Clear Failure Code2336
Failure Code [CB3254]2338
Loaded Diagnostics Operation to Clear Failure Code2345
Failure Code [CB3255]2347
Loaded Diagnostics Operation to Clear Failure Code2354
Failure Code [CB3256]2356
Loaded Diagnostics Operation to Clear Failure Code2363
Failure Code [CB3311]2365
Loaded Diagnostics Operation to Confirm Failure Correction2372
Failure Code [CB3312]2374
Loaded Diagnostics Operation to Confirm Failure Correction2381
Failure Code [CB3313]2383
Failure Code [CB3314]2386
Failure Code [CB3315]2389
Loaded Diagnostics Operation to Confirm Failure Correction2394
Failure Code [CB3316]2395
Failure Code [CB3317]2398
Failure Code [CB3318]2401
Loaded Diagnostics Operation to Confirm Failure Correction2406
Failure Code [CB3319]2408
Failure Code [CB3321]2411
Failure Code [CB3322]2414
Loaded Diagnostics Operation to Confirm Failure Correction2419
Failure Code [CB3419]2421
Failure Code [CB3421]2423
Failure Code [CB4151]2426
Failure Code [CB4158]2434
Failure Code [CB4161]2437
Failure Code [CB4162]2440
Failure Code [CB4163]2443
Loaded Diagnostics Operation to Confirm Failure Correction2445
Failure Code [CB4259]2446
Failure Code [CB4952]2449
Failure Code [CB5383]2452
Failure Code [D110L4]2454
Failure Code [D162KA]2457
Failure Code [D162KB]2458
Failure Code [D162KY]2459
Failure Code [D180KA]2460
Failure Code [D180KB]2463
Failure Code [D180KY]2466
Failure Code [D191KA]2468
Failure Code [D191KB]2471
Failure Code [D191KY]2474
Failure Code [D192KA]2476
Failure Code [D192KB]2479
Failure Code [D192KY]2482
Failure Code [D19JKZ]2484
Failure Code [D19LKA]2489
Failure Code [D19LKB]2492
Failure Code [D19LKY]2495
Failure Code [D1E6KA]2497
Failure Code [D1E6KB]2500
Failure Code [D1E6KY]2503
Failure Code [D1EFKA]2505
Failure Code [D1EFKB]2508
Failure Code [D1EFKY]2511
Failure Code [D1J0KB]2514
Failure Code [D5ZHKA]2517
Failure Code [D5ZHKB]2520
Failure Code [D5ZHKZ]2523
Failure Code [D5ZHL6]2527
Failure Code [D862KA]2530
Failure Code [DA80KY]2533
Failure Code [DA80L4]2536
Failure Code [DAF0KT]2540
Failure Code [DAF0MB]2541
Failure Code [DAF0MC]2542
Failure Code [DAF3KK]2543
Failure Code [DAF8KB]2547
Failure Code [DAFDKB]2550
Failure Code [DAFGMC]2553
Failure Code [DAFLKA]2554
Failure Code [DAFLKB]2557
Failure Code [DAFQKR]2560
Failure Code [DAQ0KK]2571
Failure Code [DAQ0KT]2576
Failure Code [DAQ0MC]2577
Failure Code [DAQ1KA]2578
Failure Code [DAQ2KK]2581
Failure Code [DAQ4KB]2585
Failure Code [DAQ9KQ]2588
Failure Code [DAQLKA]2590
Failure Code [DAQLKB]2593
Failure Code [DAQQKR]2596
Failure Code [DAQRKR]2611
Failure Code [DAQRMA]2625
Failure Code [DAZ9KQ]2626
Failure Code [DAZQKR]2628
Failure Code [DB2QKR]2639
Failure Code [DB2RKR]2657
Failure Code [DB90KK]2675
Failure Code [DB90KT]2680
Failure Code [DB90MC]2681
Failure Code [DB91KA]2682
Failure Code [DB92KK]2685
Failure Code [DB95KX]2690
Failure Code [DB96KX]2693
Failure Code [DB97KX]2698
Failure Code [DB99KQ]2701
Failure Code [DB9LKA]2703
Failure Code [DB9LKB]2706
Failure Code [DB9QKR]2709
Failure Code [DB9RKR]2725
Failure Code [DB9RMA]2741
Failure Code [DBE5KX]2743
Failure Code [DBE6KX]2746
Failure Code [DBE7KX]2749
Failure Code [DBP0KM]2753
Failure Code [DBP0KT]2755
Failure Code [DBP0NR]2756
Failure Code [DBP5KP]2757
Failure Code [DBPLKA]2761
Failure Code [DBPLKB]2765
Failure Code [DBPQKR]2768
Failure Code [DBPRKR]2782
Failure Code [DBPRMA]2795
Failure Code [DBPUKR]2796
Failure Code [DBPVKR]2806
Failure Code [DBPWKR]2814
Failure Code [DBPXKR]2816
Failure Code [DBV0MC]2818
Failure Code [DBV1KK]2819
Failure Code [DBV5KX]2824
Failure Code [DBV6KX]2828
Failure Code [DBV7KX]2832
Failure Code [DBV8KX]2833
Failure Code [DBVLKA]2834
Failure Code [DBVLKB]2838
Failure Code [DBVQK4]2841
Failure Code [DBVQKR]2855
Failure Code [DBVRKR]2869
Failure Code [DBVVKR]2883
Failure Code [DBVWKR]2884
Failure Code [DD1ALD]2886
Failure Code [DDA8KB]2889
Failure Code [DDA9KB]2892
Failure Code [DDAAL6]2895
Failure Code [DDACKA]2899
Failure Code [DDACKY]2904
Failure Code [DDADKA]2908
Failure Code [DDADKY]2912
Failure Code [DDB6L4]2914
Failure Code [DDD1LD]2918
Failure Code [DDDBKA]2921
Failure Code [DDDBKY]2925
Failure Code [DDE2KB]2928
Failure Code [DDE2L6]2931
Failure Code [DDE5KA]2933
Failure Code [DDK4KA]2936
Failure Code [DDK4KB]2940
Failure Code [DDK5L4]2944
Failure Code [DDNRKY]2947
Failure Code [DDNTKY]2950
Failure Code [DDNUKY]2953
Failure Code [DDNWKY]2956
Failure Code [DDNYKB]2958
Failure Code [DDP5KA]2961
Failure Code [DDP6KA]2964
Failure Code [DDP6KY]2967
Failure Code [DDP6NR]2970
Failure Code [DDW9LD]2972
Failure Code [DDWLLD]2975
Failure Code [DF10KA]2978
Failure Code [DF10KB]2979
Failure Code [DGE5KA]2980
Failure Code [DGE5KB]2983
Failure Code [DGF1KA]2986
Failure Code [DGF1KB]2989
Failure Code [DGH2KX]2992
Failure Code [DGR2KB]2995
Failure Code [DGR2KZ]2999
Failure Code [DGR4KB]3003
Failure Code [DGR4KZ]3007
Failure Code [DGT1KA]3011
Failure Code [DGT1KB]3014
Failure Code [DGT5KA]3017
Failure Code [DGT5KY]3022
Failure Code [DGT6KA]3026
Failure Code [DGT6KY]3031
Failure Code [DH21KA]3035
Failure Code [DH21KY]3039
Failure Code [DHA4KA]3042
Failure Code [DHAAMA]3045
Failure Code [DHABMA]3047
Failure Code [DHACMA]3049
Failure Code [DHADMA]3051
Failure Code [DHPAKA]3053
Failure Code [DHPAKY]3057
Failure Code [DHPCKA]3060
Failure Code [DHPCKY]3064
Failure Code [DHPDKA]3067
Failure Code [DHPDKY]3071
Failure Code [DHPSKA]3074
Failure Code [DHPSKY]3078
Failure Code [DHT2L6]3081
Failure Code [DHT3KX]3084
Failure Code [DHT5KX]3088
Failure Code [DHT7KX]3092
Failure Code [DHT8KA]3096
Failure Code [DHT8KY]3099
Failure Code [DHTAKX]3101
Failure Code [DHTBKA]3105
Failure Code [DHTBKY]3109
Failure Code [DHU2KA]3112
Failure Code [DHU2KY]3115
Failure Code [DHU3KA]3118
Failure Code [DHU3KY]3121
Failure Code [DJF1KA]3124
Failure Code [DK30KA]3127
Failure Code [DK30KY]3131
Failure Code [DK55KA]3134
Failure Code [DK55KY]3135
Failure Code [DK55L5]3136
Failure Code [DK59KA]3137
Failure Code [DK59KY]3141
Failure Code [DK59L8]3144
Failure Code [DK5AKA]3149
Failure Code [DK5AKY]3153
Failure Code [DK5BKA]3156
Failure Code [DK5BKY]3160
Failure Code [DK5BL8]3163
Failure Code [DK5CKA]3167
Failure Code [DK5CKY]3171
Failure Code [DKA0KA]3174
Failure Code [DKA0KY]3178
Failure Code [DKA0L0]3181
Failure Code [DKA1KA]3184
Failure Code [DKA1KY]3188
Failure Code [DKD0KA]3191
Failure Code [DKD0KY]3194
Failure Code [DKD0L8]3196
Failure Code [DKR2KX]3198
Failure Code [DKR2NX]3202
Failure Code [DKR3KX]3205
Failure Code [DKR3NX]3209
Failure Code [DLFAKA]3212
Failure Code [DLFALC]3215
Failure Code [DLFFLC]3218
Failure Code [DLM3KA]3222
Failure Code [DLM3LC]3225
Failure Code [DLT3KA]3228
Failure Code [DLT3LC]3231
Failure Code [DLT4KB]3234
Failure Code [DLT4KX]3237
Failure Code [DNDBL4]3240
Failure Code [DPQ1KR]3243
Failure Code [DPQ1LD]3249
Failure Code [DPQ2KR]3255
Failure Code [DPQ3KR]3262
Failure Code [DPQ4KB]3268
Failure Code [DQ11KQ]3270
Sensor Addresses List3274
Failure Code [DQ11KR]3275
Failure Code [DQ11KT]3278
Failure Code [DQ11MA]3281
Failure Code [DQ11NR]3285
Failure Code [DQ12KQ]3288
Sensor Addresses List3292
Failure Code [DQ12KR]3293
Failure Code [DQ12KT]3296
Failure Code [DQ12MA]3299
Failure Code [DQ12NR]3303
Failure Code [DQ13KQ]3306
Sensor Addresses List3310
Failure Code [DQ13KR]3311
Failure Code [DQ13KT]3314
Failure Code [DQ13MA]3317
Failure Code [DQ13NR]3321
Failure Code [DQ14KQ]3324
Sensor Addresses List3328
Failure Code [DQ14KR]3329
Failure Code [DQ14KT]3332
Failure Code [DQ14MA]3335
Failure Code [DQ14NR]3340
Failure Code [DR10KA]3343
Failure Code [DR20KA]3347
Failure Code [DR30KA]3351
Failure Code [DR40KA]3355
Failure Code [DR50KA]3359
Failure Code [DR60KA]3363
Failure Code [DSJ0KR]3367
Failure Code [DT22KB]3377
Failure Code [DUMBKB]3380
Failure Code [DV00KB]3383
Failure Code [DV01KB]3386
Failure Code [DW4PKA]3389
Failure Code [DW4PKB]3392
Failure Code [DW4PKY]3395
Failure Code [DW4QKA]3398
Failure Code [DW4QKB]3401
Failure Code [DW4QKY]3404
Failure Code [DW4RKA]3407
Failure Code [DW4RKB]3410
Failure Code [DW4RKY]3413
Failure Code [DW4SKA]3416
Failure Code [DW4SKB]3419
Failure Code [DW4SKY]3422
Failure Code [DW5PKA]3425
Failure Code [DW5PKB]3428
Failure Code [DW5PKY]3431
Failure Code [DW5QKA]3434
Failure Code [DW5QKB]3437
Failure Code [DW5QKY]3440
Failure Code [DW5RKA]3443
Failure Code [DW5RKB]3446
Failure Code [DW5RKY]3449
Failure Code [DW5SKA]3452
Failure Code [DW5SKB]3455
Failure Code [DW5SKY]3458
Failure Code [DW7BKA]3461
Failure Code [DW7BKB]3464
Failure Code [DW7BKY]3467
Failure Code [DWM1KA]3469
Failure Code [DWM1KB]3472
Failure Code [DWM1KY]3475
Failure Code [DWN6KA]3477
Failure Code [DWN6KB]3480
Failure Code [DWN6KY]3483
Failure Code [DWN8KA]3486
Failure Code [DWN8KB]3489
Failure Code [DWN8KY]3492
Failure Code [DWNFKA]3495
Failure Code [DWNFKB]3498
Failure Code [DWNFKY]3501
Failure Code [DWNVKA]3503
Failure Code [DWNVKB]3506
Failure Code [DWNVKY]3509
Failure Code [DX16KA]3511
Failure Code [DX16KB]3514
Failure Code [DX16KY]3517
Failure Code [DXA1KA]3519
Failure Code [DXA1KB]3522
Failure Code [DXA1KY]3525
Failure Code [DXA8KA]3527
Failure Code [DXA8KB]3530
Failure Code [DXA8KY]3533
Failure Code [DXANKA]3535
Failure Code [DXANKB]3538
Failure Code [DXANKY]3541
Failure Code [DXF0KA]3543
Failure Code [DXF0KB]3546
Failure Code [DXF0KY]3549
Failure Code [DXF5KA]3551
Failure Code [DXF5KB]3554
Failure Code [DXF5KY]3557
Failure Code [DXF6KA]3559
Failure Code [DXF6KB]3562
Failure Code [DXF6KY]3565
Failure Code [DXH4KA]3567
Failure Code [DXH4KB]3570
Failure Code [DXH4KY]3573
Failure Code [DXH5KA]3575
Failure Code [DXH5KB]3578
Failure Code [DXH5KY]3581
Failure Code [DXH6KA]3583
Failure Code [DXH6KB]3586
Failure Code [DXH6KY]3589
Failure Code [DXH7KA]3591
Failure Code [DXH7KB]3594
Failure Code [DXH7KY]3597
Failure Code [DXH8KA]3599
Failure Code [DXH8KB]3602
Failure Code [DXH8KY]3605
Failure Code [DXHPKA]3607
Failure Code [DXHPKB]3610
Failure Code [DXHPKY]3613
Failure Code [DXHPMA]3616
Failure Code [DXHPMB]3619
Troubleshooting of Electrical System (E-Mode)3622
Engine Does Not Start (Engine Does Not Crank)3622
Manual Preheating System Does Not Operate3637
Automatic Preheating System Does Not Work (For Machines Without Pre-lubrication System)3645
Automatic Preheating System Does Not Work (For Machines with Pre-lubrication System)3652
While Preheating is in Operation, Preheating Pilot Lamp Does Not Come On3659
LCD Unit, LED Unit, and Meter Unit on Machine Monitor Do Not Show Anything3663
LCD Unit on Machine Monitor Shows Nothing3673
Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers)3676
LCD Screen on Machine Monitor Does Not Show Correctly3679
Meter Unit Display on Machine Monitor is Abnormal3682
Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal3687
LED Unit Lamp on Machine Monitor is Abnormal3691
Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly3696
Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate3701
Switch Panel Buzzer of Machine Monitor is Abnormal3706
Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Correctly3711
Rearview Monitor Does Not Come On or Backlight Flickers3712
Rearview Monitor Images are Not Shown Clearly3717
Rearview Monitor Brightness Cannot be Adjusted3723
Night Mode Lamp of Rearview Monitor is Abnormal3729
Air Cleaner Clogging Caution Lamp Does Not Come On3733
Radiator Coolant Level Caution Lamp Does Not Come On3736
Parking Brake Indicator Lamp Does Not Come On When Parking Brake is ON (Parking) Position3739
Brake Oil Pressure Caution Lamp Does Not Come On When Front Brake Accumulator Oil Pressure is Low3748
Brake Oil Pressure Caution Lamp Does Not Come On When Rear Brake Accumulator Oil Pressure is Low3752
Fuel Gauge Does Not Show Normally3756
Torque Converter Oil Temperature Gauge Does Not Rise or Torque Converter Oil Temperature Caution Lamp Does Not Come On3759
Hydraulic Oil Temperature Gauge Does Not Rise or Hydraulic Oil Temperature Caution Lamp Does Not Come On3761
Seatbelt Caution Lamp Does Not Show Normally3763
Alarm Buzzer Does Not Operate3766
Alarm Buzzer Does Not Stop3768
Kickdown Does Not Operate When Kickdown Switch is ON Position3770
Hold Does Not Operate When Hold Switch is on Position3773
Parking Brake Does Not Operate Even If It is Applied, or the Brake Drags in FORWARD or REVERSE Travel When Parking Brake is Released3776
Loader Pump1 or Loader Pump 2 is Fixed to the Minimum Flow3784
ECSS Function Cannot be Selected or Cannot be Released3787
Horn Does Not Sound3790
Horn Does Not Stop3795
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On3798
Clearance Lamp and Tail Lamp Do Not Come On or Go Out3802
Headlamp Do Not Come On or Go Out3808
Side Working Lamp Does Not Come On or Go Out3814
Front Working Lamp Does Not Come On or Go Out3819
Rear Working Lamp Does Not Come On or Go Out3826
Turn Signal Lamp and Hazard Lamp Do Not Come On or Go Out3833
Turn Signal Lamp Does Not Come On or Go Out3839
Hazard Lamp Does Not Come On or Go Out3846
Brake Lamp Does Not Come On or Stays Lit3852
Backup Lamp Does Not Come On or Stays Lit3857
Staircase Light Does Not Come On or Go Out3861
Engine Room Lamp Does Not Come On or Go Out3867
Fog Lamp Does Not Come On or Go Out3872
Yellow Revolving Lamp Does Not Come On or Go Out3877
Backup Buzzer Does Not Sound or Continues to Sound3882
Front Wiper Does Not Operate3886
Rear Wiper Does Not Operate3891
Side Wiper Does Not Operate3896
Fuel Feed Pump Does Not Operate or Stop Automatically3901
Front Window Washer Does Not Operate3909
Rear Window Washer Does Not Operate3913
Side Window Washer Does Not Operate3917
Power Ladder Does Not Operate3921
Shock is Large When Power Ladder Stops3928
Parking Status Cannot be Cancelled While Power Ladder is Stored3932
Auto-Digging Function Does Not Operate3935
Semi-Auto Approach Function Does Not Operate3939
Semi-Auto Dump Function Does Not Operate3943
KOMTRAX Plus System Does Not Operate Normally3948
Data Download with Wireless LAN Does Not Operate3951
KomVision Monitor Does Not Come On or Backlight Flickers3952
KomVision Monitor Images are Not Shown Clearly3957
KomVision Monitor Brightness Cannot be Adjusted3965
Night Mode Lamp of KomVision Monitor is Abnormal3971
A Part of Camera Image of KomVision Monitor is Not Shown3975
KomVision Monitor is Not Shown Correctly After Calibration3977
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)3979
Information Shown in Troubleshooting Table (H-Mode)3979
Failure Mode and Cause Table3980
Machine Does Not Start3994
ECMV Operation Table4002
Travel Speed is Slow, Bucket Thrust Force is Weak, Gradability is Low, or Gear Speed Does Not Shift4003
ECMV Operation Table4010
Strong Shocks are Made When You Start Machine or Shift Gears4011
ECMV Operation Table4016
Time Lag is Large When You Start Machine or Shift Gears4017
ECMV Operation Table4022
Torque Converter Oil Temperature is High4023
Machine Does Not Turn4029
Turning Response is Unsatisfactory4035
Machine Sways or Large Shocks are Made While Machine Turns4041
Wheel Brakes Do Not Operate or are Weak4046
Wheel Brakes are Not Released or Drag4050
Parking Brake Does Not Operate or is Weak4052
Parking Brake is Not Released or Drags4054
Boom Does Not Rise4058
Boom Moves Slow or Lacks Lifting Force4064
Rising Boom Slows Down at Specified Height4070
Lift Cylinders Can Not Hold Bucket on Ground4071
Hydraulic Drift of Boom is Large4075
Boom Moves Up and Down During Operation4077
Bucket Does Not Tilt Back4080
Bucket Moves Slow or Lacks Tilt-Back Force4087
Bucket Slows Down During Tilt Back Operation4094
Bucket Cylinder Does Not Hold Bucket on Ground4095
Hydraulic Drift of Bucket is Large4099
Bucket Tilts Back and Forth When You Carry Load4101
Boom and Bucket Control Levers Do Not Move Smoothly and are Heavy to Move4104
Engine Speed Drops Largely or Engine Stops When You Operate Work Equipment4106
Large Shocks are Made When Work Equipment Starts to Move and Stops4110
When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves4117
ECSS Does Not Operate and Machine Pitches and Bounces4118
Fan Speed is Abnormal (Too High or Low, or Does Not Move)4121
Unusual Noise is Heard from Around Fan4125
Troubleshooting of Engine (S-Mode)4126
Information Shown in Troubleshooting Table (S-Mode)4126
Engine Does Not Crank When Starting Switch is Turned to Start Position4127
Engine Cranks but Does Not Start4129
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)4134
Engine Startability is Unsatisfactory4141
Engine Does Not Pick Up Smoothly4147
Engine Stops During Operation4154
Engine Does Not Rotate Smoothly4161
Engine Lacks Output (or Lacks Power)4167
KDPF Becomes Clogged in a Short Time4174
Engine Oil Consumption is Excessive4179
Engine Oil Becomes Dirty Quickly4183
Fuel Consumption is Excessive4187
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)4191
Engine Oil Pressure Drops4193
Fuel Mixes Into Engine Oil4197
Water Mixes Into Engine Oil (Milky)4199
Coolant Temperature Increases Too High (Overheat)4202
Unusual Noise is Heard4207
Vibration is Excessive4210
Air Cannot be Bled from Fuel Circuit4212
Active Regeneration is Done Frequently4216
Active Regeneration Continues Long4222
White Smoke is Exhausted During Active Regeneration4227
50 Disassembly and Assembly4229
Table of Contents4230
Precautions Before Work4237
Related Information on Disassembly and Assembly4238
How to Read This Manual4238
Coating Materials List4240
Special Tool List4245
Sketches of Special Tools4263
Engine and Cooling System4276
Remove and Install Supply Pump Assembly (Right Bank)4276
How to Remove Supply Pump Assembly (Right Bank)4277
How to Install Supply Pump Assembly (Right Bank)4288
Remove and Install Supply Pump Assembly (Left Bank)4307
How to Remove Supply Pump Assembly (Left Bank)4308
How to Install Supply Pump Assembly (Left Bank)4314
Remove and Install Injector Assembly (Right Bank)4325
How to Remove Injector Assembly (Right Bank)4326
How to Install Injector Assembly (Right Bank)4336
Remove and Install Injector Assembly (Left Bank)4349
How to Remove Injector Assembly (Left Bank)4350
How to Install Injector Assembly (Left Bank)4360
Remove and Install Fuel Doser Assembly (Right Bank)4373
How to Remove Fuel Doser Assembly (Right Bank)4373
How to Install Fuel Doser Assembly (Right Bank)4376
Remove and Install Fuel Doser Assembly (Left Bank)4380
How to Remove Fuel Doser Assembly (Left Bank)4380
How to Install Fuel Doser Assembly (Left Bank)4383
Remove and Install Cylinder Head Assembly (Right Bank)4387
How to Remove Cylinder Head Assembly (Right Bank)4390
How to Install Cylinder Head Assembly (Right Bank)4420
Remove and Install Cylinder Head Assembly (Left Bank)4465
How to Remove Cylinder Head Assembly (Left Bank)4468
How to Install Cylinder Head Assembly (Left Bank)4501
Remove and Install EGR Valve Assembly (Right Bank)4553
How to Remove EGR Valve Assembly (Right Bank)4554
How to Install EGR Valve Assembly (Right Bank)4564
Remove and Install EGR Valve Assembly (Left Bank)4577
How to Remove EGR Valve Assembly (Left Bank)4578
How to Install EGR Valve Assembly (Left Bank)4588
Remove and Install EGR Cooler Assembly (Right Bank)4602
How to Remove EGR Cooler Assembly (Right Bank)4603
How to Install EGR Cooler Assembly (Right Bank)4618
Remove and Install EGR Cooler Assembly (Left Bank)4640
How to Remove EGR Cooler Assembly (Left Bank)4641
How to Install EGR Cooler Assembly (Left Bank)4657
Remove and Install Starter Assembly4679
How to Remove Starting Motor Assembly4679
How to Install Starting Motor Assembly4682
Remove and Install Alternator Belt4685
How to Remove Alternator Belt4686
How to Install Alternator Belt4687
Remove and Install Alternator Assembly4690
How to Remove Alternator Assembly4691
How to Install Alternator Assembly4693
Remove and Install Cooler Assembly4698
How to Remove Cooling Assembly4700
How to Install Cooling Assembly4716
Remove and Install Radiator Core4734
How to Remove Radiator Core4735
How to Install Radiator Core4742
Remove and Install Radiator Reservoir Tank Assembly4749
How to Remove Radiator Reservoir Tank Assembly4750
How to Install Radiator Reservoir Tank Assembly4751
Remove and Install Cooling Fan and Fan Motor Assembly4753
How to Remove Cooling Fan and Fan Motor Assembly4754
How to Install Cooling Fan and Fan Motor Assembly4758
Remove and Install Hydraulic Oil Cooler Assembly4762
How to Remove Hydraulic Oil Cooler Assembly4762
How to Install Hydraulic Oil Cooler Assembly4764
Remove and Install Aftercooler Assembly4766
How to Remove Aftercooler Assembly4767
How to Install Aftercooler Assembly4772
Remove and Install Power Train Oil Cooler Assembly4777
How to Remove Power Train Oil Cooler Assembly4778
How to Install Power Train Oil Cooler Assembly4779
Remove and Install Brake Cooler4781
How to Remove Brake Cooler4782
How to Install Brake Cooler4783
Remove and Install Engine Assembly4784
How to Remove Engine Assembly4786
How to Install Engine Assembly4800
Remove and Install Engine Front Oil Seal4815
How to Remove Engine Front Oil Seal4815
How to Install Engine Front Oil Seal4817
Remove and Install Engine Rear Oil Seal4819
How to Remove Engine Rear Oil Seal4820
How to Install Engine Rear Oil Seal4821
Remove and Install Upper Part of Engine4824
How to Remove Upper Part of Engine4825
How to Install Upper Part of Engine4830
Remove and Install Top Hood Assembly4835
How to Remove Top Hood Assembly4835
How to Install Top Hood Assembly4837
Remove and Install Fuel Tank Assembly4840
How to Remove Fuel Tank Assembly4841
How to Install Fuel Tank Assembly4847
Remove and Install KDPF Assembly4852
How to Remove KDPF Assembly4853
How to Install KDPF Assembly4859
Disassemble and Assemble KDPF Assembly4867
How to Disassemble KDPF Assembly4868
How to Assemble KDPF Assembly4874
Remove and Install KCCV Assembly (Right Bank)4883
How to Remove KCCV Assembly (Right Bank)4883
How to Install KCCV Assembly (Right Bank)4887
Remove and Install KCCV Assembly (Left Bank)4891
How to Remove KCCV Assembly (Left Bank)4892
How to Install KCCV Assembly (Left Bank)4896
Remove and Install VGT Assembly (Right Bank)4901
How to Remove VGT Assembly (Right Bank)4902
How to Install VGT Assembly (Right Bank)4913
Remove and Install VGT Assembly (Left Bank)4926
How to Remove VGT Assembly (Left Bank)4927
How to Install VGT Assembly (Left Bank)4938
Remove and Install Air Cleaner Assembly4951
How to Remove Air Cleaner Assembly4951
How to Install Air Cleaner Assembly4953
Remove and Install Air Conditioner Compressor Assembly4955
How to Remove Air Conditioner Compressor Assembly4956
How to Install Air Conditioner Compressor Assembly4958
Remove and Install Air Conditioner Condenser Assembly4962
How to Remove Air Conditioner Condenser Assembly4962
How to Install Air Conditioner Condenser Assembly4965
Drain and Add Coolant4968
How to Drain Coolant4968
How to Add Coolant4970
Power Train4972
Remove and Install Damper Assembly4972
How to Remove Damper Assembly4974
How to Install Damper Assembly4977
Disassemble and Assemble Damper Assembly4979
How to Disassemble Damper Assembly4980
How to Assemble Damper Assembly4981
Remove and Install Transmission, Transfer Assembly and Torque Converter, Input Transfer, PTO Assembly4987
How to Remove Transmission, Transfer Assembly and Torque Converter, Input Transfer, PTO Assembly4991
How to Install Transmission, Transfer Assembly and Torque Converter, Input Transfer, PTO Assembly5016
Disconnect and Connect Transmission, Transfer Assembly and Torque Converter, Input Transfer, PTO Assembly5042
How to Disconnect Transmission, Transfer Assembly and Torque Converter, Input Transfer, PTO Assembly5043
How to Connect Transmission, Transfer Assembly and Torque Converter, Input Transfer, PTO Assembly5048
Disconnect and Connect Torque Converter, Input Transfer and PTO Assembly5056
How to Disconnect Torque Converter, Input Transfer, PTO Assembly5057
How to Connect Torque Converter, Input Transfer, PTO Assembly5059
Disassemble and Assemble Torque Converter Assembly5062
How to Disassemble Torque Converter Assembly5063
How to Assemble Torque Converter Assembly5065
Disassemble and Assemble Input Transfer and PTO Assembly5070
How to Disassemble Input Transfer and PTO Assembly5072
How to Assemble Input Transfer and PTO Assembly5083
Disconnect and Connect Transmission and Transfer Assembly5105
How to Disconnect Transmission and Transfer Assembly5105
How to Connect Transmission and Transfer Assembly5106
Disassemble and Assemble Transmission Assembly5108
How to Disassemble Transmission Assembly5110
How to Assemble Transmission Assembly5123
Disassemble and Assemble Transfer Assembly5138
How to Disassemble Transfer Assembly5140
How to Assemble Transfer Assembly5148
Remove and Install Parking Brake Assembly5162
How to Remove Parking Brake Assembly5163
How to Install Parking Brake Assembly5167
Disassemble and Assemble Parking Brake Assembly5170
How to Disassemble Parking Brake Assembly5171
How to Assemble Parking Brake Assembly5173
Drain and Add Transmission Oil5177
How to Drain Transmission Oil5177
How to Add Transmission Oil5178
Remove and Install Front Axle Assembly5179
How to Remove Front Axle Assembly5181
How to Install Front Axle Assembly5188
Remove and Install Rear Axle Assembly5194
How to Remove Rear Axle Assembly5196
How to Install Rear Axle Assembly5204
Remove and Install Center Support Assembly5212
How to Remove Center Support Assembly5213
How to Install Center Support Assembly5215
Disassemble and Assemble Center Support Assembly5219
How to Disassemble Center Support Assembly5219
How to Assemble Center Support Assembly5221
Remove and Install Differential Assembly5226
How to Remove Differential Assembly5227
How to Install Differential Assembly5230
Disassemble and Assemble Differential Assembly5234
How to Disassemble Differential Assembly5236
How to Assemble Differential Assembly5246
Remove and Install Final Drive Carrier Assembly5268
How to Remove Final Drive Carrier Assembly5269
How to Install Final Drive Carrier Assembly5270
Disassemble and Assemble Final Drive Carrier Assembly5273
How to Disassemble Final Drive Carrier Assembly5273
How to Assemble Final Drive Carrier Assembly5275
Remove and Install Front Final Drive and Brake Assembly5278
How to Remove Front Final Drive and Brake Assembly5279
How to Install Front Final Drive and Brake Assembly5282
Disassemble and Assemble Final Drive and Brake Assembly5287
How to Disassemble Final Drive and Brake Assembly5289
How to Assemble Final Drive and Brake Assembly5298
Steering System5315
Remove and Install Steering Valve Assembly5315
How to Remove Steering Valve Assembly5316
How to Install Steering Valve Assembly5324
Remove and Install Rotary Valve Assembly5333
How to Remove Rotary Valve Assembly5334
How to Install Rotary Valve Assembly5336
Brake System5339
Remove and Install Right Brake Valve Assembly5339
How to Remove Right Brake Valve Assembly5340
How to Install Right Brake Valve Assembly5343
Remove and Install Left Brake Valve Assembly5348
How to Remove Left Brake Valve Assembly5349
How to Install Left Brake Valve Assembly5352
Remove and Install Brake Accumulator Assembly5355
How to Remove Brake Accumulator Assembly5356
How to Install Brake Accumulator Assembly5359
Undercarriage and Frame5362
Remove and Install Front Wheel Assembly5362
How to Remove Front Wheel Assembly5362
How to Install Front Wheel Assembly5365
Remove and Install Rear Wheel Assembly5367
How to Remove Rear Wheel Assembly5368
How to Install Rear Wheel Assembly5373
Remove and Install Center Hinge Pin5379
How to Remove Center Hinge Pin5383
How to Install Center Hinge Pin5394
Remove and Install Bumper Assembly5412
How to Remove Bumper Assembly5413
How to Install Bumper Assembly5416
Hydraulic System5419
Remove and Install Hydraulic Tank Assembly5419
How to Remove Hydraulic Tank Assembly5420
How to Install Hydraulic Tank Assembly5428
Remove and Install Work Equipment Pump, Pilot and Brake Charge Pump Assembly5435
How to Remove Work Equipment Pump, Pilot and Brake Charge Pump Assembly5436
How to Install Work Equipment Pump, Pilot and Brake Charge Pump Assembly5441
Remove and Install Work Equipment Pump and Brake Cooling Duplex Pump Assembly5445
How to Remove Work Equipment Pump and Brake Cooling Duplex Pump Assembly5446
How to Install Work Equipment Pump and Brake Cooling Duplex Pump Assembly5450
Remove and Install Secondary Steering Pump Assembly5454
How to Remove Secondary Steering Pump Assembly5455
How to Install Secondary Steering Pump Assembly5456
Remove and Install Steering Pump Assembly5458
How to Remove Steering Pump Assembly5459
How to Install Steering Pump Assembly5465
Remove and Install Cooling Pump and Cooling Fan Pump Assembly5470
How to Remove Cooling Pump and Cooling Fan Pump Assembly5471
How to Install Cooling Pump and Cooling Fan Pump Assembly5476
Remove and Install Transmission and Torque Converter Lubrication Triplex Pump Assembly5482
How to Remove Transmission and Torque Converter Lubrication Triplex Pump Assembly5483
How to Install Transmission and Torque Converter Lubrication Triplex Pump Assembly5485
Remove and Install Control Valve Assembly5487
How to Remove Control Valve Assembly5488
How to Install Control Valve Assembly5500
Remove and Install Diverter Valve Assembly5512
How to Remove Diverter Valve Assembly5513
How to Install Diverter Valve Assembly5516
Drain and Add Hydraulic Oil5519
How to Drain Hydraulic Oil5519
How to Add Hydraulic Oil5521
Work Equipment5522
Remove and Install Work Equipment Assembly5522
How to Remove Work Equipment Assembly5523
How to Install Work Equipment Assembly5530
Disassemble and Assemble Steering Cylinder Assembly5538
How to Disassemble Steering Cylinder Assembly5539
How to Assemble Steering Cylinder Assembly5541
Disassemble and Assemble Bucket Cylinder Assembly5545
How to Disassemble Bucket Cylinder Assembly5546
How to Assemble Bucket Cylinder Assembly5548
Disassemble and Assemble Lift Cylinder Assembly5552
How to Disassemble Lift Cylinder Assembly5553
How to Assemble Lift Cylinder Assembly5555
Remove and Install Boom End (Bucket Hinge) Bushing5559
How to Remove Boom End (Bucket Hinge) Bushing5559
How to Install Boom End (Bucket Hinge) Bushing5560
CAB Related Parts5561
Remove and Install ROPS Assembly5561
How to Remove ROPS Assembly5562
How to Install ROPS Assembly5566
Remove and Install Operator CAB Assembly and Floor Frame Assembly5571
How to Remove Operator Cab Assembly and Floor Frame Assembly5573
How to Install Operator Cab Assembly and Floor Frame Assembly5583
Remove and Install Operator Cab Assembly5594
How to Remove Operator Cab Assembly5595
How to Install Operator Cab Assembly5610
Remove and Install Operator Cab Glass (Adhered Glass)5624
How to Remove Operator Cab Glass (Adhered Glass)5624
How to Install Operator Cab Glass (Adhered Glass)5625
Remove and Install Air Conditioner Unit Assembly5634
How to Remove Air Conditioner Unit Assembly5635
How to Install Air Conditioner Unit Assembly5641
Remove and Install Operator Seat Assembly5649
How to Remove Operator Seat Assembly5649
How to Install Operator Seat Assembly5652
Remove and Install Work Equipment Control Lever5656
How to Remove Work Equipment Control Lever5657
How to Install Work Equipment Control Lever5660
How to Remove and Install Seat Belt5664
How to Remove Seat Belt5664
How to Install Seatbelt5665
Remove and Install AJSS Lever Switch Assembly5667
How to Remove AJSS Lever Switch Assembly5668
How to Install AJSS Lever Switch Assembly5672
Electrical System5678
Remove and Install Engine Controller Assembly (Right Bank)5678
How to Remove Engine Controller Assembly (Right Bank)5679
How to Install Engine Controller Assembly (Right Bank)5681
Remove and Install Engine Controller Assembly (Left Bank)5685
How to Remove Engine Controller Assembly (Left Bank)5686
How to Install Engine Controller Assembly (Left Bank)5688
Remove and Install Work Equipment Controller Assembly5692
How to Remove Work Equipment Controller Assembly5693
How to Install Work Equipment Controller Assembly5696
Remove and Install Transmission Controller Assembly5699
How to Remove Transmission Controller Assembly5700
How to Install Transmission Controller Assembly5703
Remove and Install Monitor Controller Assembly5706
How to Remove Monitor Controller Assembly5707
How to Install Monitor Controller Assembly5710
Remove and Install Machine Monitor Assembly5713
How to Remove Machine Monitor Assembly5713
How to Install Machine Monitor Assembly5715
Remove and Install Mass Air Flow and Temperature Sensor5718
How to Remove Mass Air Flow and Temperature Sensor5718
How to Install Mass Air Flow and Temperature Sensor5719
Remove and Install KCCV Crankcase Pressure Sensor5720
How to Remove KCCV Crankcase Pressure Sensor5720
How to Install KCCV Crankcase Pressure Sensor5723
Remove and Install KDPF Temperature Sensor5727
How to Remove KDPF Temperature Sensor5727
How to Install KDPF Temperature Sensor5734
Remove and Install KDPF Differential Pressure Sensor5739
How to Remove KDPF Differential Pressure Sensor5739
How to Install KDPF Differential Pressure Sensor5744
Remove and Install KomVision Camera Assembly5749
How to Remove KomVision Camera Assembly5751
How to Install KomVision Camera Assembly5761
Remove and Install KomVision Radar Assembly5772
How to Remove KomVision Radar Assembly5774
How to Install KomVision Radar Assembly5777
Remove and Install KomVision Controller5780
How to Remove KomVision Controller5780
How to Install KomVision Controller5782
Remove And Install KOMTRAX Plus Controller Assembly5784
How to Remove KOMTRAX Plus Controller Assembly5784
How to Install KOMTRAX Plus Controller Assembly5786
Remove and Install Wireless LAN Unit Assembly5788
How to Remove Wireless LAN Unit Assembly5788
How to Install Wireless LAN Unit Assembly5790
60 Maintenance Standard5793
Table of Contents5794
Explanation of Terms for Maintenance Standard5795
Engine and Cooling System5797
Maintenance Standard for Engine Mount5797
Maintenance Standard for Damper5798
Maintenance Standard for Cooling Fan Pump5800
Maintenance Standard for Servo Valve for Cooling Fan Pump5802
Maintenance Standard for Cooling Fan Motor5803
Power Train5806
Maintenance Standard for Drive Shaft5806
Maintenance Standard for Center Support5807
Maintenance Standard for Transmission Mount5809
Maintenance Standard for Torque Flow Assembly5811
Maintenance Standard for Torque Converter5813
Maintenance Standard for Modulation Clutch5820
Maintenance Standard for Valve Assembly (For Main Relief and Torque Converter Relief)5822
Maintenance Standard for Torque Converter Regulator Valve5824
Maintenance Standard for Transmission5826
Maintenance Standard for Transmission Control Valve5834
Maintenance Standard for F, R, 1st, 2nd, 3rd Clutch ECMV5835
Maintenance Standard for Modulation Clutch ECMV5837
Maintenance Standard for Transmission Lubrication Relief Valve5839
Maintenance Standard for Front Axle5840
Maintenance Standard for Rear Axle5842
Maintenance Standard for Front Differential5844
Maintenance Standard for Rear Differential5848
Maintenance Standard for Final Drive5852
Steering System5854
Maintenance Standard for Steering Pump5854
Maintenance Standard for Steering Cylinder5857
Brake System5859
Maintenance Standard for Brake5859
Maintenance Standard for Parking Brake5861
Maintenance Standard for Parking Brake Circuit Check Valve5863
Undercarriage and Frame5864
Maintenance Standard for Frame, Axle Mount and Center Hinge Pin5864
Hydraulic System5871
Maintenance Standard for Hydraulic Tank5871
Maintenance Standard for Work Equipment Pump5873
Maintenance Standard for Control Valve5876
Work Equipment5889
Maintenance Standard for Work Equipment Linkage5889
Maintenance Standard for Bucket5893
Maintenance Standard for Lift Cylinder5894
Maintenance Standard for Bucket Cylinder5895
CAB Related Parts5896
Maintenance Standard for CAB Mount5896
80 Others5897
Table of Contents5898
Precautions Before Work5900
Air Conditioner System5901
Precautions for Refrigerant5901
Air Conditioner Component5902
Specifications of Air Conditioner5904
Structure and Function of Refrigeration Cycle5905
Outline of Refrigeration Cycle5906
Component Parts of Air Conditioner System5908
Air Conditioner Unit5908
Component Parts of Air Conditioner Unit5911
Function of Evaporator5911
Function of Heater Core5911
Function of Evaporator Temperature Sensor5911
Function of Servomotor5911
Structure of Expansion Valve5912
Function of Expansion Valve5912
Operation of Expansion Valve5912
Function of Triple Pressure Switch5913
Air Conditioner Controller5915
Structure of Air Conditioner Controller5915
Compressor5916
Structure of Compressor5916
Specifications of Compressor5916
Function of Compressor5916
Operation of Compressor5917
Condenser5918
Structure of Condenser5918
Specifications of Condenser5918
Function of Condenser5918
Receiver Drier5920
Structure of Receiver Dryer5920
Specifications of Receiver Dryer5920
Function of Receiver Dryer5920
Air Conditioner Related Sensors5921
Structure of Sunlight Sensor5921
Function of Sunlight Sensor5921
Structure of Outside Temperature Sensor5921
Function of Outside Air Temperature Sensor5921
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner5922
Circuit Diagram and Configuration of Connector Pins of Air Conditioner5924
System Diagram of Air Conditioner5926
Input and Output Signals of Air Conditioner Controller5927
Function of Air Conditioner Controller5928
Locations of Air Conditioner Parts and Layout of Connectors5929
Examine Air Leakage (Duct)5933
How to Examine Air Leakage (Duct)5933
Examine Air Conditioner with Self-Diagnosis Function5935
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor5936
Examine Vent (Mode) Changeover5937
How to Examine Vent (Mode) Changeover5937
Examine Fresh/Recirc Air Changeover5938
How to Examine Fresh/Recirc Air Changeover5938
Examine Sunlight Sensor5939
How to Examine Sunlight Sensor5939
Examine Refrigerant (Triple) Pressure Switch5940
How to Examine Refrigerant (Triple) Pressure Switch5940
Examine Relay5942
How to Examine Relay5942
Air Conditioner Troubleshooting Chart 15943
Air Conditioner Troubleshooting Chart 25945
Information Shown in Troubleshooting5948
Troubleshooting by Failure Code (Display of Code)5951
Failure Code [879AKA]5951
Failure Code [879AKB]5952
Failure Code [879BKA]5953
Failure Code [879BKB]5956
Failure Code [879CKA]5959
Failure Code [879CKB]5960
Failure Code [879DKZ]5961
Failure Code [879EMC]5965
Failure Code [879FMC]5966
Failure Code [879GKX]5967
Troubleshooting of Air Conditioner System (A-Mode)5970
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)5970
Troubleshooting for Condenser5975
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)5982
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)5987
Troubleshooting for Fresh/Recirc Air Changeover5991
Troubleshooting by Gauge Pressure5994
Connect Service Tool5998
How to Connect Service Tool5998
Precautions for Disconnection and Connection of Air Conditioner Piping5999
Handle Compressor Oil6000
KomVision System6002
Structure and Operation of KomVision System6002
Precautions for KomVision System6002
Layout Drawing of KomVision System6003
Component Parts of KomVision System6009
Examine and Adjust KomVision System6022
Set and Operate KomVision Monitor6022
Camera Calibration6042
5 Camera Calibration6043
1 Camera Calibration6068
Adjust Radar (For Machine with Radar)6075
How to Set Default Radar Setting6075
How to Adjust Radar6077
Troubleshooting for KomVision System6082
Related Information to Troubleshooting6082
Troubleshooting by Failure Code (Display of Code)6100
Troubleshooting of Electrical System (E-Mode)6279
90 Circuit Diagrams6307
Table of Contents6308
How to Read the Codes for Electric Cable6309
Hydraulic Circuit Diagram6313
Symbols Used in Hydraulic Circuit Diagram6313
Hydraulic Circuit Diagram for Work Equipment6317
Power Train Hydraulic Circuit Diagram6319
Hydraulic Circuit Diagram for Work Equipment (Combination of Forward 1st Travel, Boom RAISE and Bucket TILT Operation (1/2)6321
Hydraulic Circuit Diagram for Power Train (Combination of Forward 1st Travel, Boom RAISE and Bucket TILT Operation 2/2)6323
Hydraulic Circuit Diagram for Work Equipment (Combination of Boom LOWER, Reverse 2nd Travel, Steer Left, and Left Brake Operation 1/2)6325
Hydraulic Circuit Diagram for Power Train (Combination of Boom LOWER, Reverse 2nd Travel, Steer Left, and Left Brake Operation 2/2)6327
Electrical Circuit Diagram6329
Symbols Used in Electric Circuit Diagram6329
Electrical Circuit Diagram of Machine (1/8)6333
Electrical Circuit Diagram of Machine (2/8)6335
Electrical Circuit Diagram of Machine (3/8)6337
Electrical Circuit Diagram of Machine (4/8)6339
Electrical Circuit Diagram of Machine (5/8)6341
Electrical Circuit Diagram of Machine (6/8)6343
Electrical Circuit Diagram of Machine (7/8)6345
Electrical Circuit Diagram of Machine (8/8)6347
Electrical Circuit Diagram of Floor (1/8)6349
Electrical Circuit Diagram of Floor (2/8)6351
Electrical Circuit Diagram of Floor (3/8)6353
Electrical Circuit Diagram of Floor (4/8)6355
Electrical Circuit Diagram of Floor (5/8)6357
Electrical Circuit Diagram of Floor (6/8)6359
Electrical Circuit Diagram of Floor (7/8)6361
Electrical Circuit Diagram of Floor (8/8)6363
Electrical Circuit Diagram of Engine (1/2)6365
Electrical Circuit Diagram of Engine (2/2)6367
Index6369
S.M 30/12/24
