Komatsu Wheel Loader WA600 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu WA600, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu WA600 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEBM000800 - Wheel Loader WA600-1 Shop Manual.pdf
SEBM013217 - Wheel Loader WA600-3 avance Shop Manual.pdf
SEBM013218 - Wheel Loader WA600-3 avance Shop Manual.pdf
SEBM013219 - Wheel Loader WA600-3 avance Shop Manual.pdf
SEBM04260111 - Wheel Loader WA600-1 Shop Manual.pdf
SEBMW01400 - Wheel Loader WA600-3 avance (-50 degree Spec.) avance Shop Manual.pdf
SEN00235-18 - Wheel Loader GALEO WA600-6 Shop Manual
SEN06579 - Wheel Loader WA600-8 Shop Manual.pdf
CEAM000800 - Wheel Loader WA600-1 Operation & Maintenance Manual.pdf
CEAM003001 - Wheel Loader WA600-3 Operation & Maintenance Manual.pdf
EEAM024501 - Wheel Loader WA600-6 Operation & Maintenance Manual.pdf
GEN00036-02 - Wheel Loader GALEO WA600-6 Field Assembly Instruction.pdf
GEN00090-00 - Wheel Loader WA600-3 Field Assembly Instruction.pdf
SEAM018400 - Wheel Loader WA600-3 avance Operation & Maintenance Manual.pdf
SEAM018402T - Wheel Loader WA600-3 avance Operation & Maintenance Manual.pdf
SEAW006000 - Wheel Loader WA600-3 Field Assembly Instruction.pdf
TEN00002-02 - Wheel Loader GALEO WA600-3 Operation & Maintenance Manual.pdf
TEN00002-04 - Wheel Loader WA600-3 Operation & Maintenance Manual.pdf
TEN00111-06 - Wheel Loader GALEO WA600-6 Operation & Maintenance Manual.pdf
TEN00240-02 - Wheel Loader WA600-6 Operation & Maintenance Manual.pdf
TEN00296-02 - Wheel Loader WA600-6 Operation & Maintenance Manual.pdf
TEN00372-01 - Wheel Loader WA600-6 Operation & Maintenance Manual.pdf
TEN00462-02 - Wheel Loader WA600-6 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 9,443 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
CEAM000800 - Wheel Loader WA600-1 Operation & Maintenance Manual...1
CEAM003001 - Wheel Loader WA600-3 Operation & Maintenance Manual...202
INTRODUCTION...205
1. FORWARD...206
2. SAFETY INFORMATION...207
3. INTRODUCTION...208
3.1 INTENDED USE...208
3.2 FEATURES...208
3.3 BREAKING IN A NEW MACHINE...208
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...209
4.1 MACHINE SERIAL NO. PLATE POSITION...209
4.2 ENGINE SERIAL NO. PLATE POSITION...209
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...210
5. TABLE OF CONTENTS...211
SAFETY ...217
6. GENERAL PRECAUTIONS ...218
7. PRECAUTIONS DURING OPERATION ...224
7.1 BEFORE STARTING ENGINE ...224
7.2 AFTER STARTING ENGINE ...227
7.3 TRANSPORTATION ...235
7.4 BATTERY ...236
7.5 TOWING ...239
8. PRECAUTIONS FOR MAINTENANCE ...240
8.1 BEFORE CARRYING OUT MAINTENANCE ...240
8.2 DURING MAINTENANCE ...245
8.3 TIRES ...251
9. SAFETY LABELS ...253
9.1 POSITION FOR ATTACHING SAFETY LABELS ...253
OPERATION ...258
10. GENERAL VIEW ...259
10.1 GENERAL VIEW OF MACHINE ...259
10.2 GENERAL VIEW OF CONTROLS AND GAUGES ...260
10.2.1 CONTROLS...260
10.2.2 MAIN MONITOR...260
10.2.3 MAINTENANCE MONITOR...261
11. EXPLANATION OF COMPONENTS ...262
11.1 MACHINE MONITORS ...262
11.1.1 WARNING DISPLAYS...264
11.1.2 METER DISPLAY PORTION...269
11.2 SWITCHES ...273
11.3 LEVERS AND PEDALS ...281
11.4 CAB DOOR HOLD-OPEN LOCK ...285
11.5 AIR CLEANER SERVICE INDICATOR ...285
11.6 FRAME LOCKING BAR ...285
11.7 FUSE BOXES ...286
11.8 FUSE ARRANGEMENT AND CIRCUIT ...286
11.9 SLOW-BLOW FUSE ...288
11.10 AIR CONDITIONER MAINTENANCE IN OFF- SEASON ...288
11.11 COOL BOX ...288
11.12 TANK FILLER CAPS AND LOCKS ...289
11.12.1 FUEL TANK...289
11.12.2 HYDRAULIC FLUID TANK...289
12. OPERATING MACHINE ...290
12.1 CHECKS BEFORE STARTING ...290
12.1.1 WALK-AROUND CHECK...290
12.1.2 CHECK BEFORE STARTING...292
12.1.3 ADJUSTMENT BEFORE OPERATION...292
12.1.4 OPERATIONS BEFORE STARTING THE ENGINE...295
12.2 STARTING THE ENGINE ...296
12.2.1 NORMAL STARTING...296
12.2.2 SPECIAL STARTING...296
12.2.3 COLD WEATHER STARTING...297
12.3 OPERATIONS AFTER STARTING THE ENGINE ...298
12.3.1 COLD WEATHER WARM-UP PROCEDURE...298
12.4 MOVING THE MACHINE ...300
12.5 CHANGING GEAR SPEED ...302
12.6 SHIFTING BETWEEN FORWARD AND REVERSE ...303
12.7 STEERING ...303
12.8 STOPPING THE MACHINE ...304
12.9 OPERATION OF WORK EQUIPMENT ...305
12.10 WORK POSSIBLE USING WHEEL LOADER ...306
12.10.1 DIGGING PILED GROUND...306
12.10.2 DIGGING LEVEL GROUND...308
12.10.3 LEVELING OPERATION...309
12.10.4 PUSHING OPERATION...309
12.10.5 LOAD AND CARRY OPERATIONS...309
12.10.6 LOADING OPERATIONS...310
12.11 PRECAUTIONS FOR OPERATION ...311
12.11.1 PERMISSIBLE WATER DEPTH...311
12.11.2 IF THE WHEEL BRAKE DOES NOT WORK...311
12.11.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...311
12.11.4 PRECAUTIONS WHEN DRIVING THE MACHINE...312
12.12 ADJUSTING THE WORK EQUIPMENT POSITIONERS ...313
12.12.1 ADJUSTING BOOM KICK-OUT...313
12.12.2 ADJUSTING BUCKET POSITIONER...314
12.12.3 BUCKET LEVEL INDICATOR...314
12.13 PARKING THE MACHINE ...315
12.14 CHECKS AFTER COMPLETION OF OPERATION ...317
12.15 STOPPING ENGINE ...317
12.16 CHECK AFTER STOPPING THE ENGINE ...317
12.17 LOCKING ...317
12.18 HANDLING THE TIRES ...318
12.18.1 PRECAUTIONS WHEN HANDLING TIRES...318
12.18.2 TIRE PRESSURE...318
12.19 REMOVAL AND INSTALLATION OF THE BUCKET ...320
12.19.1 REMOVING THE BUCKET...320
12.19.2 INSTALLING THE BUCKET...322
13. TRANSPORTATION ...324
13.1 LOADING AND UNLOADING ...324
13.2 PRECAUTIONS FOR LOADING ...325
13.3 LIFTING THE MACHINE ...325
13.3.1 LIFT POINT MARKINGS...326
13.3.2 WEIGHT TABLE...326
13.3.3 LIFTING PROCEDURE...326
13.4 PRECAUTIONS FOR TRANSPORTATION ...327
14. COLD WEATHER OPERATION ...328
14.1 FUEL AND LUBRICANTS ...328
14.2 COOLANT ...328
14.3 BATTERY ...328
14.4 PRECAUTIONS AFTER COMPLETION OF WORK ...329
14.5 AFTER COLD WEATHER ...329
14.6 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER ...329
15. LONG TERM STORAGE ...330
15.1 BEFORE STORAGE ...330
15.2 DURING STORAGE ...330
15.3 AFTER STORAGE ...330
16. TROUBLESHOOTING ...331
16.1 WHEN MACHINE RUNS OUT OF FUEL ...331
16.2 TOWING THE MACHINE ...331
16.2.1 WHEN ENGINE CAN BE USED...332
16.2.2 WHEN ENGINE CANNOT BE USED...332
16.2.3 RELEASING PARKING BRAKE...333
16.2.4 EMERGENCY TRAVEL OPERATION...334
16.3 IF THE BATTERY IS DISCHARGED ...335
16.3.1 REMOVAL AND INSTALLATION OF BATTERY...335
16.3.2 PRECAUTIONS FOR CHARGING THE BATTERY...336
16.3.3 STARTING THE ENGINE WITH BOOSTER CABLES...337
16.4 OTHER TROUBLE ...339
16.4.1 ELECTRICAL SYSTEM...339
16.4.2 CHASSIS...340
16.4.3 ENGINE...343
16.4.4 RELATIONSHIP OF ELECTRONIC CONTROL SYSTEM...345
MAINTENANCE ...348
17. GUIDES TO MAINTENANCE ...349
18. OUTLINES OF SERVICE ...351
18.1 OUTLINE OF OIL, FUEL, AND COOLANT ...351
18.1.1 OIL...351
18.1.2 FUEL...352
18.1.3 COOLANT...352
18.1.4 STORING OIL AND FUEL...353
18.1.5 FILTERS...353
18.2 FUEL INJECTION PUMP ...353
18.3 OUTLINE OF ELECTRIC SYSTEM ...353
19. WEAR PARTS LIST ...354
20. LUBRICANTS, FUEL, AND COOLANT ...355
20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ...355
20.2 ENGINE OIL ...356
20.2.1 NORMAL OPERATION...356
20.2.2 ARCTIC OPERATION...356
20.3 TRANSMISSION, HYDRAULIC SYSTEM, BRAKE SYSTEM OIL ...357
20.4 AXLE OIL ...357
20.5 GREASE ...357
20.6 DIESEL FUEL ...357
20.7 COOLANT SPECIFICATIONS ...358
20.7.1 GENERAL...358
20.7.2 WATER...358
20.7.3 ANTIFREEZE...358
20.7.4 SUPPLEMENTAL COOLANT ADDITIVES...359
20.7.5 TOOLS...362
21. STANDARD TIGHTENING TORQUE FOR NUTS AND BOLTS ...363
21.1 INTRODUCTION OF NECESSARY TOOLS ...363
21.2 TORQUE LIST...364
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ...365
23. MAINTENANCE SCHEDULE CHART ...367
24. SERVICE PROCEDURE ...371
24.1 INITIAL 250 HOURS SERVICE ...371
24.2 WHEN REQUIRED ...372
24.2.1 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...372
24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL...374
24.2.3 CHECK AXLE OIL LEVEL, ADD OIL...376
24.2.4 CHECK AXLE CASE BREATHER...377
24.2.5 CLEAN RADIATOR CORE...377
24.2.6 REPLACE BOLT-ON CUTTING EDGE...378
24.2.7 REPLACE BUCKET TEETH...379
24.2.8 CHECK AIR CONDITIONER...380
24.2.9 CLEAN CONDENSER OF AIR CONDITIONER...381
24.2.10 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...381
24.2.11 LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE (2 POINTS)...381
24.2.12 REPLACE SLOW BLOW FUSE...382
24.3 CHECKS BEFORE STARTING ...383
24.3.1 CHECK MONITOR PANEL...383
24.3.2 CHECK COOLANT LEVEL, ADD COOLANT...383
24.3.3 CHECK FUEL LEVEL, ADD FUEL...384
24.3.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...384
24.3.5 CHECK ELECTRICAL WIRING...385
24.3.6 CHECK EFFECT OF PARKING BRAKE...386
24.3.7 CHECK EFFECT OF WHEEL BRAKES...386
24.3.8 CHECK SOUND OF HORN AND BACKUP ALARM...386
24.3.9 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE...386
24.3.10 CHECK ENGINE EXHAUST COLOR AND SOUND...386
24.3.11 CHECK OPERATIONS OF GAUGES...386
24.3.12 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING...386
24.3.13 DRAIN WATER FROM FUEL FILTER...386
24.3.14 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE...386
24.4 EVERY 50 HOURS SERVICE ...387
24.4.1 CHECK THE TIRE INFLATION PRESSURE...387
24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK...387
24.4.3 CHECK ENGINE AIR INTAKE SYSTEM...387
24.5 EVERY 100 HOURS SERVICE ...388
24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...388
24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...389
24.5.3 LUBRICATE REAR AXLE PIVOT PIN (3 PLACES)...389
24.6 EVERY 250 HOURS SERVICE ...390
24.6.1 CHANGE OIL AND REPLACE ENGINE OIL FILTER CARTRIDGE...390
24.6.2 REPLACE FUEL FILTERS...392
24.6.3 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN...393
24.6.4 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...393
24.6.5 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...394
24.6.6 CHECK BATTERY ELECTROLYTE LEVEL...395
24.6.7 LUBRICATING...396
24.6.8 CHECK FRAME AND BOOM...399
24.6.9 REPLACE COOLANT FILTER...399
24.7 EVERY 500 HOURS SERVICE ...401
24.7.1 REPLACE TRANSMISSION OIL FILTER...401
24.7.2 LUBRICATE CENTER DRIVE SHAFT SPLINE...401
24.8 EVERY 1000 HOURS SERVICE ...402
24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...402
24.8.2 CLEAN TRANSMISSION CASE BREATHER...403
24.8.3 LUBRICATING (DRIVE TRAIN)...404
24.9 EVERY 1500 HOURS SERVICE ...406
24.9.1 CHECK AND ADJUST ENGINE VALVES AND INJECTORS...406
24.9.2 CHECK AND REPLACE (AS REQUIRED) ENGINE MOUNTED HOSES...406
24.9.3 CHECK AND RETIGHTEN ENGINE MOUNTING HARDWARE...407
24.9.4 CHECK TURBOCHARGER MOUNTING...407
24.9.5 CHECK WATER PUMP...407
24.9.6 CHECK TENSION OF DRIVE BELT...408
24.9.7 CHECK DRIVE BELT TENSIONER BEARING AND FAN HUB BEARING...408
24.10 EVERY 2000 HOURS SERVICE ...410
24.10.1 CHANGE OIL IN HYDRAULIC TANK, REPLACE FILTER ELEMENT...410
24.10.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT...412
24.10.3 CHANGE, CLEAN, AND FLUSH COOLING SYSTEM...413
24.10.4 CLEAN RADIATOR FINS...416
24.10.5 CHANGE AXLE OIL...417
24.10.6 REPLACE ELEMENT IN AIR CONDITIONER RECIRCUCLATION AIR FILTER, FRESH AIR FILTER...418
24.10.7 CLEAN P.P.C. (PROPORTIONAL PRESSURE CONTROL) CIRCUIT STRAINER...418
24.10.8 CHECK BRAKE DISC WEAR...419
24.10.9 CHECK ACCUMULATOR...419
24.10.10 STEAM CLEAN THE ENGINE...419
24.11 EVERY 6000 HOURS SERVICE...420
24.11.1 CLEAN AND CALIBRATE FUEL PUMP...420
24.11.2 CLEAN AND CALIBRATE FUEL INJECTORS...420
24.11.3 CHECK ENGINE FAN HUB...420
24.11.4 CHECK ENGINE IDLER PULLEY...420
24.11.5 CHECK TURBOCHARGER...420
24.11.6 CHECK AIR COMPRESSOR...420
24.11.7 CHECK ENGINE VIBRATION DAMPER...420
SPECIFICATIONS ...421
25. SPECIFICATIONS ...422
OPTIONS, ATTACHMENTS ...424
26. OPTIONAL PARTS AND ATI=ACHMENTS ...425
27. SELECTING BUCKETS AND TIRES ...426
28. RADIO ...427
28.1 EXPLANATION OF PARTS ...427
28.2 METHOD OF USE ...429
28.2.1 METHOD OF AUTOMATIC TUNING...430
28.2.2 METHOD OF MANUAL TUNING...430
28.2.3 METHOD OF SETTING PRESET BUTTONS...430
28.2.4 METHOD OF AUTOMATIC MEMORY...430
28.2.5 AUTOMATIC MONAURAUSTEREO SWITCHING...430
28.2.6 ADJUSTING TIME...431
28.3 PRECAUTIONS WHEN USING ...431
29. AIR CONDITIONER ...432
29.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL ...432
29.2 METHOD OF OPERATION ...434
30. AUTO-GREASING SYSTEM ...435
30.1 METHOD OF OPERATING AUTO-GREASING SYSTEM ...435
30.1.1LUBRICATION CONTROLLER DISPLAY TABLE...435
30.1.2 ACTUATION OF AUTO-GREASING...437
30.1.3 SETTING GREASING TIME...438
30.1.4 METHOD OF SETTING...438
30.1.5 REPLACEMENT OF GREASE CARTRIDGE...440
30.1.6 METHOD OF FILLING AUTO-GREASING SYSTEM WITH GREASE...441
30.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM ...444
30.3 TROUBLESHOOTING (AUTO-GREASING SYSTEM) ...444
30.4 SPECIFICATIONS...445
31. AUTO SHIFT SYSTEM ...446
31.1 METHOD OF OPERATING ...446
31.2 PRECAUTIONS WHEN CHANGING DIRECTION ...447
32. E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM) ...448
32.1 STRUCTURE AND FUNCTION OF E.C.S.S. ...448
32.2 OPERATING E.C.S.S. ...448
32.3 PRECAUTIONS WHEN OPERATING E.C.S.S. SWITCH ...449
32.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR ...449
32.5 REMOVAL OF TRAVEL DAMPER PIPING ...450
33. JOYSTICK STEERING SYSTEM ...451
33.1 STRUCTURE AND FUNCTION OF JOYSTICK STEERING ...451
33.2 OPERATION METHOD OF JOYSTICK STEERING SYSTEM...454
33.3 PRECAUTIONS FOR STEERING WITH JOYSTICK...455
33.4 ADJUSTMENT OF JOYSTICK CONSOLE...456
34. GROUND DRIVEN STEERING ...457
CEBM000800 - Wheel Loader WA600-1 Shop Manual...459
EEAM024501 - Wheel Loader WA600-6 Operation & Maintenance Manual...1412
FOREWORD...1414
FOREWORD...1415
SAFETY INFORMATION...1416
Noise emission levels...1418
Vibration levels...1418
Guide to Reduce Vibration Levels on Machine...1419
INTRODUCTION...1420
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...1420
VISIBILITY FROM OPERATOR'S SEAT...1421
VISIBILITY IN IMMEDIATE AREA...1421
12-M RADIUS VISIBILITY...1421
NECESSARY INFORMATION...1422
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...1422
EPA REGULATIONS, ENGINE NUMBER PLATE...1422
POSITION OF SERVICE METER...1423
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...1423
MACHINE SERIAL NUMBER PLATE...1424
FOREWORD...1425
SAFETY...1425
OPERATION...1426
MAINTENANCE...1429
SPECIFICATIONS...1431
ATTACHMENTS, OPTIONS...1431
INDEX...1432
COLOPHON...1432
SAFETY...1434
SAFETY...1435
SAFETY LABELS...1437
LOCATION OF SAFETY LABELS...1438
SAFETY LABELS...1439
GENERAL PRECAUTIONS...1447
PRECAUTIONS FOR OPERATION...1457
STARTING ENGINE...1457
OPERATION...1459
TRANSPORTATION...1465
BATTERY...1466
TOWING...1468
PRECAUTIONS FOR MAINTENANCE...1469
PRECAUTIONS WITH TIRES...1477
OPERATION...1478
GENERAL VIEW...1479
GENERAL VIEW OF MACHINE...1479
GENERAL VIEW OF CONTROLS AND GAUGES...1480
EXPLANATION OF COMPONENTS...1485
MACHINE MONITOR...1485
TYPES OF WARNING...1486
CENTRAL WARNING LAMP...1487
CHARACTER DISPLAY PORTION...1487
EMERGENCY STOP ITEMS...1493
CAUTION ITEMS...1496
INSPECTION AND MAINTENANCE ITEMS...1499
PILOT DISPLAY PORTION...1502
METER DISPLAY PORTION...1508
OTHER FUNCTIONS OF MACHINE MONITOR...1510
SWITCHES...1521
FRONT PANEL, AJSS LEVER SWITCH, REAR BOX...1521
RIGHT SWITCH PANEL, CONTROL LEVER SWITCH...1529
OVERHEAD PORTION...1538
CONTROL LEVERS, PEDALS...1542
CAP WITH LOCK...1549
METHOD OF OPENING AND CLOSING CAP WITH LOCK (FOR THE FUEL TANK FILLER PORT)...1549
METHOD OF OPENING AND CLOSING CAP WITH LOCK (FOR THE HYDRAULIC TANK FILLER PORT)...1550
FRAME LOCK BAR...1551
TOWING PIN...1552
BACKUP ALARM...1552
OPENING CAB, WINDOW DOOR...1553
OPEN LOCK CANCEL KNOB FOR RIGHT CAB DOOR...1553
CAB LEFT DOOR OPEN KNOB...1554
OPEN LOCK CANCEL KNOB FOR LEFT CAB WINDOW...1554
HANDLING CAB WIPER...1555
PREVENTING DAMAGE TO WIPER ARM BRACKET...1555
DUST INDICATOR...1555
FUSE...1556
FUSE CAPACITY AND NAME OF CIRCUIT...1556
CIRCUIT BREAKER...1557
SLOW BLOW FUSE...1558
LUNCH BOX TRAY...1558
TOOL BOX...1558
GREASE PUMP...1559
LOCATION OF FIRE EXTINGUISHER...1559
POWER OUTLET...1559
AM/FM RADIO-CASSETTE STEREO...1560
EXPLANATION OF COMPONENTS...1560
METHOD OF OPERATION...1565
PRECAUTIONS WHEN USING...1567
AIR CONDITIONER...1568
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL...1568
METHOD OF OPERATION...1572
USE AIR CONDITIONER WITH CARE...1578
AIR CONDITIONER MAINTENANCE...1579
COOL BOX...1579
OTHER FUNCTIONS...1579
OPERATION...1581
CHECK BEFORE STARTING ENGINE, ADJUST...1581
WALK-AROUND CHECK...1581
CHECK BEFORE STARTING...1584
ADJUSTMENT...1591
OPERATIONS AND CHECKS BEFORE STARTING ENGINE...1596
STARTING ENGINE...1597
AUTOMATIC WARMING-UP OPERATION...1599
OPERATIONS AND CHECKS AFTER STARTING ENGINE...1599
BREAKING-IN THE MACHINE...1599
NORMAL OPERATION...1600
STOPPING ENGINE...1601
CHECK AFTER STOPPING ENGINE...1601
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...1602
PREPARATIONS FOR MOVING MACHINE...1602
CHANGING GEAR SPEED...1605
CHANGING DIRECTION...1606
STOPPING THE MACHINE...1607
TURNING...1609
EMERGENCY STEERING...1610
OPERATION OF WORK EQUIPMENT...1611
SEMI AUTO DIGGING OPERATIONS...1612
REMOTE POSITIONER...1613
WORK POSSIBLE USING WHEEL LOADER...1615
RECOMMENDED COMBINATION OF SWITCHES FOR OPERATION...1615
DIGGING OPERATIONS...1616
LEVELING OPERATIONS...1619
PUSHING OPERATION...1619
LOAD AND CARRY OPERATIONS...1619
LOADING OPERATIONS...1620
PRECAUTIONS WHEN HANDLING BLASTED ROCK...1622
PRECAUTIONS FOR OPERATION...1634
PERMISSIBLE WATER DEPTH...1634
IF WHEEL BRAKE DOES NOT WORK...1634
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...1634
REMOVAL AND INSTALLATION OF THE BUCKET...1636
REMOVING THE BUCKET...1636
INSTALLING THE BUCKET...1638
PARKING MACHINE...1640
CHECKS AFTER COMPLETION OF OPERATION...1642
LOCKING...1642
HANDLING THE TIRES...1643
PRECAUTIONS WHEN HANDLING TIRES...1643
TIRE PRESSURE...1643
PRECAUTIONS FOR USING LOAD AND CARRY METHOD...1645
PRECAUTIONS FOR USING STONE HANDLING METHOD...1645
PRECAUTIONS RELATED TO FITTING TIRE CHAINS AND ADDING BALLAST...1645
TRANSPORTATION...1646
TRANSPORTATION PROCEDURE...1646
LOADING, UNLOADING WORK...1646
METHOD OF SECURING MACHINE...1646
METHOD OF LIFTING MACHINE...1648
LOCATION OF LIFTING POSITION MARK...1649
WEIGHT TABLE...1649
LIFTING PROCEDURE...1650
PRECAUTIONS WHEN DISASSEMBLY OR REASSEMBLING WORK EQUIPMENT...1651
COLD WEATHER OPERATION...1652
PRECAUTIONS FOR LOW TEMPERATURE...1652
FUEL AND LUBRICANTS...1652
COOLANT...1652
BATTERY...1653
PRECAUTIONS AFTER COMPLETION OF WORK...1653
AFTER COLD WEATHER...1654
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...1654
LONG-TERM STORAGE...1655
BEFORE STORAGE...1655
DURING STORAGE...1655
AFTER STORAGE...1655
TROUBLESHOOTING...1656
WHEN MACHINE RUNS OUT OF FUEL...1656
METHOD OF TOWING MACHINE...1656
WHEN ENGINE RUNS...1657
WHEN ENGINE DOES NOT RUN...1657
RELEASING PARKING BRAKE...1658
EMERGENCY TRAVEL OPERATION...1659
IF BATTERY IS DISCHARGED...1660
REMOVAL AND INSTALLATION OF BATTERY...1660
PRECAUTIONS FOR CHARGING BATTERY...1661
STARTING ENGINE WITH BOOSTER CABLE...1661
STARTING ENGINE WHEN USING STARTING AID CONNECTOR (if equipped)...1663
METHOD FOR LOWERING WORK EQUIPMENT WHEN ENGINE HAS STOPPED...1664
OTHER TROUBLE...1665
ELECTRICAL SYSTEM...1665
CHASSIS...1666
ENGINE...1668
MAINTENANCE...1670
GUIDES TO MAINTENANCE...1671
OUTLINES OF SERVICE...1673
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...1673
OIL...1673
FUEL...1674
COOLANT AND WATER FOR DILUTION...1674
GREASE...1675
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)...1675
STORING OIL AND FUEL...1676
FILTERS...1676
OUTLINE OF ELECTRIC SYSTEM...1677
WEAR PARTS...1678
WEAR PARTS LIST...1678
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...1679
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...1680
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...1682
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...1683
TORQUE LIST...1683
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...1685
SAFETY CRITICAL PARTS...1686
MAINTENANCE SCHEDULE CHART...1688
MAINTENANCE SCHEDULE CHART...1688
SERVICE PROCEDURE...1690
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)...1690
INITIAL 250 HOURS SERVICE...1690
WHEN REQUIRED...1691
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...1691
CLEAN INSIDE OF COOLING SYSTEM...1693
CHECK TRANSMISSION OIL LEVEL, ADD OIL...1697
CHECK AXLE OIL LEVEL, ADD OIL...1699
CLEAN AXLE CASE BREATHER...1700
CLEAN AIR CONDITIONER CONDENSER...1701
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...1701
CLEAN RADIATOR FINS...1702
REPLACE BUCKET TEETH...1706
LUBRICATING...1707
CHECK AIR CONDITIONER...1708
REPLACE SLOW BLOW FUSE...1709
BLEEDING AIR FROM HYDRAULIC TANK...1710
BLEEDING AIR FROM FUEL CIRCUIT...1712
CHECKING FUNCTION OF ACCUMULATOR...1715
SELECTION AND INSPECTION OF TIRES...1715
CHECK BEFORE STARTING...1717
EVERY 50 HOURS SERVICE...1718
DRAIN WATER, SEDIMENT FROM FUEL TANK...1718
EVERY 100 HOURS SERVICE...1719
LUBRICATING...1719
LUBRICATE REAR AXLE PIVOT PIN...1721
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...1722
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...1723
EVERY 250 HOURS SERVICE...1724
CHECK BATTERY ELECTROLYTE LEVEL...1724
CHECK PARKING BRAKE...1725
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...1726
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...1726
CHECKING FUNCTION OF ACCUMULATOR...1726
EVERY 500 HOURS SERVICE...1727
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...1727
REPLACE FUEL PRE-FILTER CARTRIDGE...1728
REPLACE FUEL FILTER CARTRIDGE...1730
REPLACE TRANSMISSION OIL FILTER ELEMENT...1731
REPLACE BRAKE OIL FILTER CARTRIDGE...1732
CHECK, REPLACE COMPRESSOR DRIVE BELT FOR ALTERNATOR, AIR CONDITIONER...1733
EVERY 1000 HOURS SERVICE...1734
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...1734
CLEAN TRANSMISSION CASE BREATHER...1735
LUBRICATING...1735
REPLACE CORROSION RESISTOR CARTRIDGE...1736
CHECK, GREASE COMPRESSOR DRIVE BELT TENSION PULLEY ASSEMBLY FOR ALTERNATOR, AIR CONDITIONER...1737
EVERY 2000 HOURS SERVICE...1738
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...1738
CLEAN HYDRAULIC TANK STRAINER...1740
REPLACE HYDRAULIC TANK BREATHER ELEMENT...1741
CHANGE AXLE OIL...1741
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...1742
CLEAN PPC CIRCUIT STRAINER...1743
CHECK ALTERNATOR...1743
CHECK ENGINE VALVE CLEARANCE, ADJUST...1743
CHECK BRAKE DISC WEAR...1743
CHECKING FUNCTION OF ACCUMULATOR...1744
CHECK BOOST PIPING CLAMPS...1744
CHANGE OIL FOR WORK EQUIPMENT PINS...1745
EVERY 4000 HOURS SERVICE...1746
CHECK WATER PUMP...1746
CHECK STARTING MOTOR...1746
CHECK AIR CONDITIONER COMPRESSOR, ADJUST...1746
LUBRICATING...1746
CHECK FOR LOOSE ENGINE HIGH-PRESSURE PIPING CLAMPS, HARDENING OF RUBBER...1748
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER...1749
EVERY 8000 HOURS SERVICE...1750
REPLACE ENGINE HIGH-PRESSURE PIPING CLAMPS...1750
REPLACE FUEL SPRAY PREVENTION CAP...1750
OVERHAUL STARTING MOTOR AND ALTERNATOR...1750
SPECIFICATIONS...1752
SPECIFICATIONS...1753
ATTACHMENTS, OPTIONS...1758
HANDLING STEERING WHEEL SPECIFICATION MACHINE...1759
EXPLANATION OF COMPONENTS...1759
SWITCHES, FRONT PANEL, STEERING WHEEL SWITCH, REAR BOX...1759
CONTROL LEVERS, PEDALS...1765
STEERING TILT LEVER...1768
FUNCTIONS OF STEERING WHEEL SPECIFICATION MACHINE...1769
CHANGING GEAR SPEED...1769
CHANGING DIRECTION...1770
TURNING...1772
MOVING MACHINE OFF (MACHINES EQUIPPED WITH STEERING WHEEL)...1773
METHOD OF STOPPING, PARKING MACHINE (MACHINES EQUIPPED WITH STEERING WHEEL)...1776
SELECTING BUCKET AND TIRES...1778
STARTING IN COLD AREAS...1779
ELECTRIC HEATER...1779
PROCEDURE FOR SETTING UP EXTERNAL POWER SOURCE FOR EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER...1779
MANUFACTURING EXTERNAL POWER SOURCE INPUT CABLE...1781
ESTABLISHING POWER SUPPLY...1782
CHECK ACTUATION AFTER COMPLETION OF ASSEMBLY...1782
HANDLING LOAD METER...1783
OUTLINE OF LOAD METER...1783
PRINCIPLE OF LOAD METER MEASUREMENT...1784
POINTS TO REMEMBER TO ENSURE HIGH ACCURACY...1785
USING LOAD METER...1787
SETTING ADDITION MODE...1787
SETTING SUBTRACTION MODE...1787
TOTAL LOAD DATA DISPLAY...1791
CLEARING TOTAL LOAD...1792
STOPPING LOAD METER CALCULATION...1792
SELECTING LOAD MATERIAL CATEGORY DISPLAY...1794
CALIBRATING WITH EMPTY BUCKET...1794
CALIBRATION WITH LOADED BUCKET...1797
RESETTING CALIBRATION...1800
METHOD OF USING ADDITION MODE...1801
METHOD OF USING SUBTRACTION MODE...1803
PRINTOUT FROM LOAD METER...1807
SELECTION OF PRINTOUT MODE...1808
HANDLING AUTO-GREASING SYSTEM...1811
METHOD OF OPERATING AUTO-GREASING SYSTEM...1811
SETTING GREASING TIME...1813
METHOD OF SETTING...1814
CHECK AMOUNT OF GREASE...1815
GREASING...1816
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM...1817
TROUBLESHOOTING...1817
HANDLING BATTERY DISCONNECTOR SWITCH...1818
EXPLANATION OF COMPONENTS...1818
BATTERY DISCONNECTOR SWITCH...1818
HANDLING...1818
HANDLING STARTING AID CONNECTOR...1820
STARTING ENGINE WHEN USING STARTING AID CONNECTOR...1820
HANDLING REAR FENDER...1822
HANDLING...1822
HANDLING MACHINES EQUIPPED WITH VHMS...1823
VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED...1823
BASIC PRECAUTIONS...1823
VHMS AND COMMUNICATIONS TERMINAL INSTALLED...1823
BASIC PRECAUTIONS...1823
INDEX...1826
<A>...1828
<B>...1828
<C>...1828
<D>...1828
<E>...1828
<F>...1828
<G>...1828
<H>...1828
<I>...1828
<L>...1828
<M>...1828
<N>...1828
<O>...1828
<P>...1828
<R>...1829
<S>...1829
<T>...1829
<U>...1829
<W>...1829
COLOPHON...1830
GEN00036-02 - Wheel Loader GALEO WA600-6 Field Assembly Instruction...1832
COVER...1832
CONTENTS...1833
1 BLOCK OUTLINE...1835
2 PRINCIPAL COMPONENT DIMENSION TABLE...1836
3 WORK SPACE LAYOUT...1837
4 GENERAL ASSEMBLY SCHEDULE...1838
5 LIST OF EQUIPMENT, JIGS, TOOLS AND CONSUMABLES...1839
6 OIL, GREASE AND PAINTS ...1842
7 ASSEMBLY PROCEDURE...1843
0010 OIL AND COOLANT...1843
0020 OIL AND COOLANT CAPACITY ...1844
0030 SETTING THE FRONT AXLE AND BARE MACHINE TO STATIONARY POSITION...1845
0040 INSTALLING THE FRONT AXLE...1846
0060 CONNECTING THE DRIVE SHAFT ...1847
0065 CONNECTING THE BRAKE PIPE ...1848
0066 CONNECTING THE BRAKE PIPE (BRAKE COOLING SPECIFICATION) ...1849
0070 INSTALLING TIRE AND RIM ASSEMBLY ...1850
0080 INSTALLING STEP ...1851
0090 INSTALLING CAB (1) ...1852
0100 INSTALLING CAB (2) (AJSS SPECIFICATION)...1853
0110 INSTALLING CAB (2) (STEERING WHEEL SPECIFICATION) ...1854
0115 INSTALLING CAB (2) (AJSS AND STEERING WHEEL SPECIFICATION)...1855
0120 INSTALLING CAB (3) ...1856
0130 INSTALLING CAB (4) (AJSS SPECIFICATION) ...1857
0140 INSTALLING CAB (4) (STEERING WHEEL SPECIFICATION) ...1858
0141 INSTALLING CAB (5) (STEERING WHEEL SPECIFICATION) ...1859
0145 INSTALLING CAB (6) (AJSS AND STEERING WHEEL SPECIFICATION) ...1860
0150 INSTALLING CAB HARNESS (1/2)...1861
0160 INSTALLING CAB HARNESS (2/2)...1862
0170 INSTALLING CAB DUCT (1/3) ...1863
0180 INSTALLING CAB DUCT (2/3) ...1864
0190 INSTALLING CAB DUCT (3/3) ...1865
0195 INSTALLATION OF YELLOW ROTARY LAMP ...1866
0200 INSTALLING FRONT FENDER ...1867
0210 INSTALLING FRONT LIGHT SUPPORT AND CONNECTION...1868
0220 INSTALLING MUFFLER STACK AND MIRROR ...1869
0230 INSTALLING COUNTERWEIGHT (STANDARD AND 1 TON HEAVIER COUNTERWEIGHT SPECIFICATIONS) ...1870
0235 INSTALLING COUNTERWEIGHT (LOAD AND CARRY SPECIFICATION)...1871
0240 INSTALLING PIN (STANDARD AND EU SPECIFICATIONS) ...1872
0250 INSTALLING REAR ACCESS LADDER AND L.H. PLATFORM...1873
0260 INSTALLING THE LEFT HANDRAIL...1874
0270 INSTALLING RIGHT PLATFORM AND R.H. HANDRAIL...1875
0275 INSTALLING FIRE EXTINGUISHER...1876
0280 INSTALLING THE REAR FENDER MUDGUARD PLATE ...1877
0290 INSTALLING REAR FENDER ...1878
0300 INSTALLING CAB UNDERCOVER...1879
0310 CHECKING OF SECTIONS ...1880
0320 AIR BLEEDING OF WORK EQUIPMENT HYDRAULIC CIRCUIT AND RESPECTIVE CYLINDERS...1881
0330 STARTING ENGINE (1/2) ...1882
0340 STARTING ENGINE (2/2)...1883
0345 BLEEDING AIR FROM BRAKE SYSTEM ...1884
0350 INSTALLING LIFT ARM AND BELL CRANK ASSEMBLY...1885
0360 INSTALLING BUCKET CYLINDER (BELL CRANK SIDE)...1886
0370 INSTALLING BUCKET (1/3)...1887
0380 INSTALLING BUCKET (2/3) ...1888
0390 INSTALLING BUCKET (3/3) ...1889
0400 GREASING (1ST TIME) ...1890
0410 INSTALLING LIFT ARM POSITIONER...1891
0420 CONTENTS OF ADJUSTMENT ITEMS ...1892
0430 SETTING OF MACHINE MONITOR ...1893
0440 ADJUSTMENT OF WORK EQUIPMENT CONTROLLER LIFT ARM ANGLE ...1894
0450 ADJUSTMENT OF WORK EQUIPMENT EPC STARTING CURRENT (1/2)...1895
0460 ADJUSTMENT OF WORK EQUIPMENT EPC STARTING CURRENT (2/2) ...1896
0470 ADJUSTMENT OF BUCKET POSITIONER (1/2) ...1897
0480 ADJUSTMENT OF BUCKET POSITIONER (2/2)...1898
0490 ADJUSTMENT OF LOAD METER LIFT ARM ANGLE...1899
0500 LOAD METER NO-LOAD CALIBRATION ...1900
0510 DELETING THE ELECTRICAL SYSTEM FAILURE HISTORY (1/2) ...1901
0520 DELETING THE ELECTRICAL SYSTEM FAILURE HISTORY (2/2)...1902
0530 INSTALLING THE FLOOR MAT (AJSS SPECIFICATION) ...1903
0540 INSTALLING THE FLOOR MAT (STEERING WHEEL SPECIFICATION) ...1904
0550 RUNNING-IN PROCEDURE (1/2) ...1905
0560 RUNNING-IN PROCEDURE (2/2) ...1906
0570 GREASING (2ND TIME) ...1907
0580 TOUCH UP WORK ...1908
0590 ON USE OF STARTER KIT (DUMMY HARNESS) AND PRECAUTION ON ITS USE ...1909
0600 STARTER KIT (DUMMY HARNESS) ASSEMBLING PROCEDURE...1910
FIELD ASSEMBLY INSPECTION REPORT...1911
GEN00090-00 - Wheel Loader WA600-3 Field Assembly Instruction...1925
COVER...1925
CONTENTS...1926
[1] DRAWINGS OF UNITS DIVIDED FOR DELIVERY...1928
[2] WEIGHT AND DIMENSIONS TABLE OF UNITS DIVIDED FOR DELIVERY...1928
[3] ASSEMBLY WORK SCHEDULE...1929
[4] NECESSARY DEVICES AND TOOLS...1929
[5] ASSEMBLY PROCEDURE...1930
(1) INSTALLATION OF TIRE AND WHEEL ASSEMBLY...1930
1) Positioning of vehicle...1930
2) Removal of axle stand...1930
3) Slinging of tire and wheel assembly...1930
4) Installation of tire and wheel assembly...1931
(2) INSTALLATION OF MUFFLER STACK...1932
(3) INSTALLATION OF CAB ASSEMBLY...1933
1) Removal of floor frame undercovers...1933
2) Removal of cover in cab assembly...1933
3) Slinging of cab assembly...1933
4) Loosening of steering post lower bolt...1934
5) Operation of steering tilt lever...1934
6) Installation of seal...1934
7) Lowering of cab assembly...1935
8) Temporary tightening of steering post fixing bolts...1935
9) Temporary tightening of cab assembly mounting bolts...1936
10) Permanent tightening of steering post lower bolt...1936
11) Permanent tightening of steering post fixing bolt...1936
12) Connection of wiring connectors and washer vinyl tubes...1937
13) Installation of troubleshooting switch...1937
14) Installation of cover in cab assembly...1937
15) Installation of steering post lower bellows...1938
16) Installation of cab assembly right-hand cover...1938
17) Installation of floor frame lower cover...1939
18) Installation of mirrors and mirror stays...1939
(4) INSTALLATION OF ROPS CANOPY...1940
1) Removal of antenna...1940
2) Removal of rear frame ROPS support bolts tightened temporarily...1940
3) Slinging of ROPS canopy...1940
4) Installation of ROPS canopy...1941
5) Installation of antenna to ROPS canopy...1941
6) Installation of antennal wire hole grommet...1941
(5) INSTALLATION OF BUCKET...1942
1) Installation of cord ring...1942
2) Aligning of bucket assembly and hinge pin holes...1942
3) Selection of shim for bucket hinge pin...1942
4) Insertion of bucket hinge pin...1943
5) Installation of bucket hinge pin stopper...1943
6) Installation of bucket hinge pin and retainer...1943
7) Lowering of cord ring to groove...1944
8) Installation of bucket link pin...1944
9) Installation of grease nipple and plug...1945
10) Measurement of steering wheel operating effort...1945
Field assembly inspection report...1946
SEAM018400 - Wheel Loader WA600-3 avance Operation & Maintenance Manual...1962
COVER...1962
1. FOREWORD...1963
2. SAFETY INFORMATION...1964
3. INTRODUCTION...1965
4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...1966
5. CONTENTS...1967
SAFETY...1971
6. GENERAL PRECAUTIONS...1972
7. PRECAUTIONS DURING OPERATION...1977
7.1 BEFORE STARTING ENGINE...1977
7.2 AFTER STARTING ENGINE...1980
7.3 TRANSPORTATION...1988
7.4 BATTERY...1989
7.5 TOWING...1991
8. PRECAUTIONS FOR MAINTENANCE...1992
8.1 BEFORE CARRYING OUT MAINTENANCE...1992
8.2 DURING MAINTENANCE...1997
8.3 TIRES...2003
9. POSITION FOR ATTACHING SAFETY LABELS...2005
OPERATION...2010
10. GENERAL VIEW...2011
10.1 GENERAL VIEW OF MACHINE...2011
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...2012
11. EXPLANATION OF COMPONENTS...2013
11.1 MACHINE MONITOR...2013
11.2 SWITCHES...2023
11.3 CONTROL LEVERS,PEDALS...2031
11.4 STEERING COLUMN TILT LEVER...2035
11.5 CAP WITH LOCK...2035
11.6 SAFETY BAR...2036
11.7 TOWING PIN...2037
11.8 GREASE PUMP...2037
11.9 BACKUP ALARM...2037
11.10 DOOR-OPEN LOCK...2038
11.11 TOOL BOX...2038
11.12 OIL FILLER PLATE...2038
11.13 FUSE...2039
11.14 SLOW-BLOW FUSE...2040
11.15 LUNCH BOX TRAY...2041
11.16 STORAGING PLACE OF THIS MANUAL...2041
11.17 TAKING OFF POWER...2041
11.18 AM/FM CAR RADIO...2042
11.19 AM/FM RADIO-CASSETTE STEREO ...2046
11.20 AIR CONDITIONER...2055
12. OPERATION...2058
12.1 CHECK BEFORE STARTING ENGINE...2058
12.2 STARTING ENGINE...2073
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE...2079
12.4 MOVING MACHINE OFF...2080
12.5 CHANGING GEAR SPEED...2082
12.6 CHANGING DIRECTION...2083
12.7 TURNING...2083
12.8 STOPPING MACHINE...2084
12.9 OPERATION OF WORK EQUIPMENT...2085
12.10 WORK POSSIBLE USING WHEEL LOADER...2086
12.11 PRECAUTIONS FOR OPERATION...2091
12.12 ADJUSTING WORK EQUIPMENT POSTURE...2093
12.13 PARKING MACHINE...2095
12.14 CHECKS AFTER COMPLETION OF OPERATION...2096
12.15 STOPPING ENGINE...2096
12.16 CHECK AFTER STOPPING ENGINE...2097
12.17 LOCKING...2097
12.18 HANDLING THE TIRES...2098
12.19 REMOVAL AND INSTALLATION OF THE BUCKET...2100
13. TRANSPORTATION...2104
13.1 LOADING, UNLOADING WORK...2104
13.2 PRECAUTIONS FOR LOADING...2105
13.3 LIFTING MACHINE...2105
13.4 PRECAUTIONS FOR TRANSPORTATION...2108
14. COLD WEATHER OPERATION...2109
14.1 PRECAUTIONS FOR LOW TEMPERATURE...2109
14.2 PRECAUTIONS AFTER COMPLETION OF WORK...2111
14.3 AFTER COLD WEATHER...2111
14.4 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...2112
15. LONG-TERM STORAGE...2113
15.1 BEFORE STORAGE...2113
15.2 DURING STORAGE...2113
15.3 AFTER STORAGE...2113
16. TROUBLESHOOTING...2114
16.1 WHEN MACHINE RUNS OUT OF FUEL...2114
16.2 TOWING THE MACHINE...2115
16.3 IF BATTERY IS DISCHARGED...2119
16.4 OTHER TROUBLE...2123
MAINTENANCE...2132
17. GUIDES TO MAINTENANCE...2133
18. OUTLINES OF SERVICE...2136
18.1 OUTLINE OF OIL,FUEL,COOLANT...2136
18.2 OUTLINE OF ELECTRIC SYSTEM...2139
19. WEAR PARTS LIST...2140
20. USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...2141
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...2145
21.1 INTRODUCTION OF NECESSARY TOOLS...2145
21.2 TORQUE LIST...2146
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...2147
23. MAINTENANCE SCHEDULE CHART...2150
23.1 MAINTENANCE SCHEDULE CHART...2150
24. SERVICE PROCEDURE...2154
24.1 INITIAL 250 HOURS SERVICE...2154
24.2 WHEN REQUIRED...2155
24.3 CHECK BEFORE STARTING...2173
24.4 EVERY 50 HOURS SERVICE...2178
24.5 EVERY 100 HOURS SERVICE...2179
24.6 EVERY 250 HOURS SERVICE...2181
24.7 EVERY 500 HOURS SERVICE...2189
24.8 EVERY 1000 HOURS SERVICE...2193
24.9 EVERY 2000 HOURS SERVICE...2198
24.10 EVERY 4000 HOURS SERVICE...2205
SPECIFICATIONS...2206
25. SPECIFICATIONS...2207
OPTIONS,ATTACHMENTS...2209
26. OPTIONAL PARTS AND ATTACHMENTS...2210
27. SELECTING BUCKETS AND TIRES...2211
28. HANDLING AUTO-GREASING SYSTEM...2212
28.1 METHOD OF OPERATING AUTO-GREASING SYSTEM...2212
28.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM...2221
28.3 TROUBLESHOOTING...2222
28.4 SPECIFICATIONS...2222
29. HANDLING AUTO SHIFT SYSTEM...2223
29.1 METHOD OF OPERATING...2223
29.2 PRECAUTIONS WHEN CHANGING DIRECTION...2224
30. HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)...2225
30.1 STRUCTURE AND FUNCTION OF E.C.S.S...2225
30.2 METHOD OF OPERATING E.C.S.S...2226
30.3 PRECAUTIONS WHEN OPERATING E.C.S.S. SWITCH...2226
30.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR...2227
30.5 REMOVAL OF TRAVEL DAMPER PIPING...2228
31. HANDLING JOYSTICK STEERING SYSTEM...2229
31.1 STRUCTURE AND FUNCTION OF JOYSTICK STEERING...2229
31.2 OPERATION METHOD OF JOYSTICK STEERING SYSTEM...2234
31.3 PRECAUTIONS FOR STEERING WITH JOYSTICK...2236
31.4 ADJUSTMENT OF JOYSTICK CONSOLE...2238
31.5 ADJUSTMENT OPERATOR'S SEAT...2239
SEAM018402T - Wheel Loader WA600-3 avance Operation & Maintenance Manual...2242
COVER...2242
1.FOREWORD...2243
2.SAFETY INFORMATION...2244
3.INTRODUCTION...2245
4.LOCATION OF PLATES,TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR...2246
5.CONTENTS...2247
SAFETY...2251
6.GENERAL PRECAUTIONS...2252
7.PRECAUTIONS DURING OPERATION...2257
7.1 BEFORE STARTING ENGINE...2257
7.2 AFTER STARTING ENGINE...2260
7.3 TRANSPORTATION...2268
7.4 BATTERY...2269
7.5 TOWING...2271
8.PRECAUTIONS FOR MAINTENANCE...2272
8.1 BEFORE CARRYING OUT MAINTENANCE...2272
8.2 DURING MAINTENANCE...2277
8.3 TIRES...2283
9.POSITION FOR ATTACHING SAFETY LABELS...2285
OPERATION...2290
10.GENERAL VIEW...2291
10.1 GENERAL VIEW OF MACHINE...2291
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...2292
11.EXPLANATION OF COMPONENTS...2293
11.1 MACHINE MONITOR...2293
11.2 SWITCHES...2303
11.3 CONTROL LEVERS,PEDALS...2311
11.4 STEERING COLUMN TILT LEVER...2315
11.5 CAP WITH LOCK...2315
11.6 SAFETY BAR...2316
11.7 TOWING PIN...2317
11.8 GREASE PUMP...2317
11.9 BACKUP ALARM...2317
11.10 DOOR-OPEN LOCK...2318
11.11 TOOL BOX...2318
11.12 OIL FILLER PLATE...2318
11.13 FUSE...2319
11.14 SLOW-BLOW FUSE...2320
11.15 LUNCH BOX TRAY...2321
11.16 STORAGING PLACE OF THIS MANUAL...2321
11.17 TAKING OFF POWER...2321
11.18 AM/FM CAR RADIO...2322
11.19 AM/FM RADIO-CASSETTE STEREO...2326
11.20 AIR CONDITIONER...2335
12.OPERATION...2338
12.1 CHECK BEFORE STARTING ENGINE...2338
12.2 STARTING ENGINE...2353
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE...2359
12.4 MOVING MACHINE OFF...2360
12.5 CHANGING GEAR SPEED...2362
12.6 CHANGING DIRECTION...2363
12.7 TURNING...2363
12.8 STOPPING MACHINE...2364
12.9 OPERATION OF WORK EQUIPMENT...2365
12.10 WORK POSSIBLE USING WHEEL LOADER...2366
12.11 PRECAUTIONS FOR OPERATION...2371
12.12 ADJUSTING WORK EQUIPMENT POSTURE...2373
12.13 PARKING MACHINE...2375
12.14 CHECKS AFTER COMPLETION OF OPERATION...2376
12.15 STOPPING ENGINE...2376
12.16 CHECK AFTER STOPPING ENGINE...2377
12.17 LOCKING...2377
12.18 HANDLING THE TIRES...2378
12.19 REMOVAL AND INSTALLATION OF THE BUCKET...2380
13.TRANSPORTATION...2384
13.1 LOADING,UNLOADING WORK...2384
13.2 PRECAUTIONS FOR LOADING...2385
13.3 LIFTING MACHINE...2385
13.4 PRECAUTIONS FOR TRANSPORTATION...2388
14.COLD WEATHER OPERATION...2389
14.1 PRECAUTIONS FOR LOW TEMPERATURE...2389
14.2 PRECAUTIONS AFTER COMPLETION OF WORK...2391
14.3 AFTER COLD WEATHER...2391
14.4 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...2392
15.LONG-TERM STORAGE...2393
15.1 BEFORE STORAGE...2393
15.2 DURING STORAGE...2393
15.3 AFTER STORAGE...2393
16.TROUBLESHOOTING...2394
16.1 WHEN MACHINE RUNS OUT OF FUEL...2394
16.2 TOWING THE MACHINE...2395
16.3 IF BATTERY IS DISCHARGED...2399
16.4 OTHER TROUBLE...2403
MAINTENANCE ...2412
17.GUIDES TO MAINTENANCE...2413
18.OUTLINES OF SERVICE...2416
18.1 OUTLINE OF OIL,FUEL,COOLANT...2416
18.2 OUTLINE OF ELECTRIC SYSTEM...2419
19.WEAR PARTS LIST...2420
20.USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...2421
21.STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...2425
21.1 INTRODUCTION OF NECESSARY TOOLS...2425
21.2 TORQUE LIST...2426
22.PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...2427
23.MAINTENANCE SCHEDULE CHART...2430
23.1 MAINTENANCE SCHEDULE CHART...2430
24.SERVICE PROCEDURE...2434
24.1 INITIAL 250 HOURS SERVICE...2434
24.2 WHEN REQUIRED...2435
24.3 CHECK BEFORE STARTING...2453
24.4 EVERY 50 HOURS SERVICE...2458
24.5 EVERY 100 HOURS SERVICE...2459
24.6 EVERY 250 HOURS SERVICE...2461
24.7 EVERY 500 HOURS SERVICE...2469
24.8 EVERY 1000 HOURS SERVICE...2473
24.9 EVERY 2000 HOURS SERVICE...2478
24.10 EVERY 4000 HOURS SERVICE...2485
SPECIFICATIONS...2486
25.SPECIFICATIONS...2487
OPTIONS,ATTACHMENTS...2489
26.OPTIONAL PARTS AND ATTACHMENTS...2490
27.SELECTING BUCKETS AND TIRES...2491
28.HANDLING AUTO-GREASING SYSTEM...2492
28.1 METHOD OF OPERATING AUTO-GREASING SYSTEM...2492
28.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM...2501
28.3 TROUBLESHOOTING...2502
28.4 SPECIFICATIONS...2502
29.HANDLING AUTO SHIFT SYSTEM...2503
29.1 METHOD OF OPERATING...2503
29.2 PRECAUTIONS WHEN CHANGING DIRECTION...2504
30.HANDLING E.C.S.S.(ELECTRONIC CONTROLLED SUSPENSION SYSTEM)...2505
30.1 STRUCTURE AND FUNCTION OF E.C.S.S...2505
30.2 METHOD OF OPERATING E.C.S.S...2506
30.3 PRECAUTIONS WHEN OPERATING E.C.S.S. SWITCH...2506
30.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR...2507
30.5 REMOVAL OF TRAVEL DAMPER PIPING...2508
31.HANDLING JOYSTICK STEERING SYSTEM...2509
31.1 STRUCTURE AND FUNCTION OF JOYSTICK STEERING...2509
31.2 OPERATION METHOD OF JOYSTICK STEERING SYSTEM...2514
31.3 PRECAUTIONS FOR STEERING WITH JOYSTICK...2516
31.4 ADJUSTMENT OF JOYSTICK CONSOLE...2518
31.5 ADJUSTMENT OPERATOR'S SEAT...2519
SEAW006000 - Wheel Loader WA600-3 Field Assembly Instruction...2522
COVER...2522
CONTENTS...2523
[1] DRAWINGS OF UNITS DIVIDED FOR DELIVERY...2525
[2] WEIGHT AND DIMENSIONS TABLE OF UNITS DIVIDED FOR DELIVERY...2525
[3] ASSEMBLY WORK SCHEDULE...2526
[4] NECESSARY DEVICES AND TOOLS...2526
[5] ASSEMBLY PROCEDURE...2527
(1) INSTALLATION OF TIRE AND WHEEL ASSEMBLY...2527
1) POSITIONING FO VEHICLE...2527
2) REMOVAL OF AXLE STAND...2527
3) SLINGING OF TIRE AND WHEEL ASSEMBLY...2527
4) INSTALLATION OF TIRE AND WHEEL ASSEMBLY...2528
(2) INSTALLATION OF MUFFLER STACK...2529
(3) INSTALLATION OF CAB ASSEMBLY...2530
1) REMOVAL OF FLOOR FRAME UNDERCOVERS...2530
2) REMOVAL OF COVER IN CAB ASSEMBLY...2530
3) SLINGING OF CAB ASSEMBLY...2530
4) LOOSENING OF STEERING POST LOWER BOLT...2531
5) OPERATION OF STEERING TILT LEVER...2531
6) INSTALLATION OF SEAL...2531
7) LOWERING OF CAB ASSEMBLY...2532
8) TEMPORARY TIGHTENING OF STEERRING POST FIXING BOLTS...2532
9) TEMPORARY TIGHTENING OF CAB ASSEMBLY MOUNTING BOLTS...2533
10) PERMANENT TIGHTENING OF STEERING POST LOWER BOLT...2533
11) PERMANENT TIGHTENING OF STEERING POST FIXING BOLT...2533
12) CONNECTION OF WIRING CONNECTORS AND WASHER VINYL TUBES...2534
13) INSTALLATION OF TROUBLESHOOTING SWITCH...2534
14) INSTALLATION OF COVER IN CAB ASSEMBLY...2534
15) INSTALLATION OF STEERING POST LOWER BELLOWS...2535
16) INSTALLATION OF CAB ASSEMBLY RIGHT-HAND COVER...2535
17) INSTALLATION OF FLOOR FRAME LOWER COVER...2536
18) INTALLATION OF MIRRORS AND MIRROR STAYS...2536
(4) INSTALLATION OF ROPS CANOPY...2537
1) REMOVAL OF ANTENNA...2537
2) REMOVAL OF REAR FRAME ROPS SUPPORT BOLTS TIGHTENED TEMPORARILY...2537
3) SLINGING OF ROPS CANOPY...2537
4) INSTALLATION OF ROPS CANOPY...2538
5) INSTALLATION OF ANTENNA TO ROPS CANOPY...2538
6) INSTALLATION OF ANTENAL WIRE HOLE GROMMET...2538
(5) INSTALLATION OF BUCKET...2539
1) INSTALLATION OF CORD RING...2539
2) ALIGHNIG OF BUCKET ASSEMBLY AND HINGE PIN HOLES...2539
3) SELECTION OF SHIM FOR BUCKET HINGE PIN...2539
4) INSERTION OF BUCKET HINGE PIN...2540
5) INSTALLATION OF BUCKET HINGE PIN STOPPER...2540
6) INSTALLATION OF BUCKET HINGE PIN AND RETAINER...2540
7) LOWERING OF CORD RING TO GROOVE...2541
8) INSTALLATION OF BUCKET LINK PIN...2541
9) INSTALLATION OF GREASE NIPPLE AND PLUG...2542
10) MEASUREMENT OF STEERING WHEEL OPERATING EFFORT...2542
SEBM013217 - Wheel Loader WA600-3 avance Shop Manual...2543
COVER...2543
CONTENTS...2544
01 GENERAL...2571
GENERAL ASSEMBLY DRAWING...2572
SPECIFICATIONS...2577
WEIGHT TABLE...2583
LIST OF LUBRICANT AND COOLANT...2586
10 STRUCTURE AND FUNCTION...2588
POWER TRAIN...2589
POWER TRAIN SYSTEM...2590
RADIATOR,HYDRAULIC OIL COOLER...2594
RADIATOR, HYDRAULIC OIL COOLER (WITH SUCTION FAN)...2597
TORQUE CONVERTER AND TRANSMISSION PIPING...2599
HYDRAULIC CIRCUIT FOR POWER TRAIN...2601
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN...2603
TORQUE CONVERTER...2607
TORQUE CONVERTER REGULATOR VALVE (SERIAL NO.:52001 AND UP)...2613
TRANSMISSION...2615
TRANSMISSION CONTROL VALVE...2624
TORQUE CONVERTER OIL COOLER...2644
TORQUE CONVERTER OIL FILTER...2645
TRANSFER...2647
DRIVE SHAFT...2648
CENTER SUPPORT...2649
AXLE...2650
DIFFERENTIAL...2652
LIMITED SLIP DIFFERENTIAL(OP)...2655
FINAL DRIVE...2659
AXLE MOUNT...2662
CENTER HINGE PIN...2664
STEERING PIPING...2665
STEERING COLUMN...2667
STEERING UNIT (ORBIT-ROLL VAVLE)...2668
STEERING VALVE...2671
TWO-WAY RESTRICTION VALVE...2682
STOP VALVE...2683
EMERGENCY STEERING PIPING...2684
DIVERTER VALVE (FOR EMERGENCY STEERING)...2685
BRAKE PIPING...2688
BRAKE CIRCUIT DIAGRAM...2692
BRAKE VALVE...2696
CHARGE VALVE...2703
ACCUMULATOR (FOR BRAKE)...2707
SLACK ADJUSTER...2708
BRAKE...2712
PARKING BRAKE...2715
SPRING CYLINDER...2717
PARKING BRAKE SOLENOID VALVE...2718
HYDRAULIC PIPING...2719
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...2723
WORK EQUIPMENT LEVER LINKAGE...2727
HYDRAULIC TANK...2728
ACCUMULATOR (FOR PPC VALVE)...2730
PPC VALVE...2731
PPC RELIEF VALVE...2735
CUT-OFF VALVE...2736
MAIN CONTROL VALVE...2738
AUTO GREASE SYSTEM...2752
LUBRICATION OF WORK EQUIPMENT...2764
WORK EQUIPMENT LINKAGE...2766
BUCKET...2768
BUCKET POSITIONER AND BOOM KICK-OUT...2769
OPERATION OF PROXIMITY SWITCH...2772
ROPS CANOPY...2776
CAB...2777
CAR HEATER...2778
AIR CONDITIONER...2780
ELECTRIC CIRCUIT DIAGRAM...2784
MACHINE MONITOR SYSTEM...2789
MAIN MONITOR...2791
MANITENANCE MONITOR...2795
MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL...2797
ENGINE STARTING CIRCUIT...2813
ENGINE STOP CIRCUIT...2816
AUTO PRIMING SYSTEM (APS) (SERIAL NO.:50001-52000)...2818
PRE-HEATING CIRCUIT (SERIAL NO.:52001 AND UP)...2822
ELECTRIC TRANSMISSION CONTROL...2823
KICK-DOWN,HOLD SWITCH...2826
KICK-DOWN ELECTRICAL CIRCUIT...2827
ELECTRIC PARKING BRAKE CONTROL...2833
E.C.S.S.(ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)...2842
20 TESTING AND ADJUSTING...2856
STANDARD VALUE TABLE FOR ENGINE...2857
STANDARD VALUE TABLE FOR CHASSIS...2859
STANDARD VALUE TABLE FOR ELECTRICAL PARTS...2869
TESTING AND ADJUSTING...2882
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...2883
MEASURING ENGINE SPEED...2886
MEASURING EXHAUST GAS COLOR...2890
ADJUSTING VALVE CLEARANCE...2891
TESTING AND ADJUSTING INJECTOR LIFT (SERIAL NO.:52001 AND UP)...2893
MEASURING COMPRESSION PRESSURE...2895
MEASURING BLOW-BY PRESSURE...2898
MEASURING ENGINE OIL PRESSURE...2899
TESTING AND ADJUSTING FUEL INJECTON TIMING (SERIAL NO.:50001-52000)...2900
REPLACING FAN BELT ADJUSTING AUTO-TENSIONER...2902
TESTING AND ADJUSTING ALTERNATOR BELT TENSION...2903
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR...2904
HANDLING EQUIPMENT IN FUEL CIRCUIT (SERIAL NO.:52001 AND UP)...2905
MEASURING FUEL PUMP OUTPUT PORT PRESSURE (SERIAL NO.:52001 AND UP)...2905
BLEEDING AIR FROM FUEL CIRCUIT (SERIAL NO.:52001 AND UP)...2906
MEASURING EXHAUST TEMPERATURE...2908
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)...2911
ADJUSTING SPEED SENSOR...2912
ADJUSTIN FUEL CONTROL CABLE (SERIAL NO.:50001-52000)...2913
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE (SERIAL NO.:50001-52000)...2914
TESTING AND ADJUSTING TORQUE CONVERTER,TRANSMISSION OIL PRESSURE...2916
PROCEDURE FOR FLUSHING TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT...2925
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS...2926
TESTING AND ADJUSTING STEERING OIL PRESSURE...2930
TESTING AND ADJUSTING STEERING STOP VALVE...2932
TESTING BRAKE OIL PRESSURE...2933
MEASURING WEAR OF BRAKE DISC...2934
MEASURING BRAKE PERFORMANCE...2935
TESTING AND ADJUSTING PARKING BRAKE...2936
TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE...2938
TESTING AND ADJUSTING PPC OIL PRESSURE...2939
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE...2941
ADJUSTING WORK EQUIPMENT LEVER LINKAGE...2943
TESTING AND ADJUSTING OF BUCKET POSITIONER...2945
TESTING AND ADJUSTING OF BOOM KICK-OUT...2946
TESTING PROXIMITY SWITCH ACTUATION PILOT LAMP...2947
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)...2948
BLEEDING AIR...2949
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...2950
TROUBLESHOOTING...2953
POINTS TO REMEMBER WHEN TROUBLESHOOTING...2954
SEQUENCE OF EVENTS IN TROUBLESHOOTING...2955
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...2956
CHECKS BEFORE TROUBLESHOOTING...2964
CONNECTOR TYPES AND MOUNTING LOCATIONS...2965
CONNECTOR ARRANGEMENT DIAGRAM...2968
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...2980
METHOD OF USING TROUBLESHOOTING CHARTS...3003
METHOD OF USING MATRIX TROUBLESHOOTING TABLES...3005
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...3007
METHOD OF USING TROUBLESHOOTING CHART...3008
S-1 STARTING PERFORMANCE IS POOR (STARING ALWAYS TAKES TIME)...3012
S-2 ENGINE DOES NOT START...3014
(1) ENGINE DOES NOT TURN...3014
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...3015
(3) EXHAUST GAS SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...3016
S-3 ENGINE DOES NOT PICK-UP SMOOTHLY (FOLLOW-UP IS POOR)...3017
S-4 ENGINE STOPS DURING OPERATIONS...3018
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...3019
S-6 ENGINE LACKS OUTPUT...3020
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...3021
S-8 OIL COMSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...3022
S-9 OIL BECOMES CONTAMINATED QUICKLY...3023
S-10 FUEL CONSUMPTION IS EXCESSIVE...3024
S-11 OIL IS COOLING, OR COOLANT SPURTS BACK,OR COOLANT LEVEL GOES DOWN...3025
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)...3026
S-13 OIL LEVEL RISES...3027
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...3028
S-15 ABNORMAL NOISE IS MADE...3029
S-16 VIBRATION IS EXCESSIVE...3030
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (EA MODE)...3031
METHOD OF ERROR CODE DISPLAY...3033
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED...3035
SCHEMATIC DIAGRAM FOR ENGINE CONTROL SYSTEM...3043
EA-1 ERROR CODE [111] (ABNORMALITY IN CONTROLLER MEMORY)...3045
EA-2 ERROR CODE [112] (ABNORMALITY IN TIMING RAIL ACTUATOR)...3045
EA-3 ERROR CODE [113] (ABNORMALITY WITH ELECTRIC CURRENT IN TIMING RAIL ACTUATOR SYSTEM)...3046
EA-4 ERROR CODE [115] (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEM)...3047
EA-5 ERROR CODE [116] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL)...3049
EA-6 ERROR CODE [117] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM LOW LEVEL)...3050
EA-7 ERROR CODE [118] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM HIGH LEVEL)...3051
EA-8 ERROR CODE [119] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM LOW LEVEL)...3052
EA-9 ERROR CODE [121] (ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEM)...3053
EA-10 ERROR CODE [122] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM HIGH LEVEL)...3054
EA-11 ERROR CODE [123] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM LOW LEVEL)...3055
EA-12 ERROR CODE [131] (ABNORMALITY IN ACCELERATOR SENSOR SYSTEM HIGH LEVEL)...3056
EA-13 ERROR CODE [132] (ABNORMALITY IN ACCELERATOR SENSOR SYSTEM LOW LEVEL)...3057
EA-14 ERROR CODE [135] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM HIHG LEVEL)...3058
EA-15 ERROR CODE [141] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM LOW LEVEL)...3059
EA-16 ERROR CODE [143] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 1))...3060
EA-17 ERROR CODE [144] (ABNORMALITY IN COOLANT TEMPERATURE SENSOR SYSTEM HIGH LEVEL)...3061
EA-18 ERROR CODE [145] (ABNORMALITY IN COOLANT TEMPERATURE SENSOR SYSTEM LOW LEVEL)...3062
EA-19 ERROR CODE [151] (ABNORMALITY RISE IN WATER TEMPERATURE)...3062
EA-20 ERROR CODE [153] (ABNORMALITY IN INTAKE AIR TEMPERATURE SENSOR SYSTEM HIGH LEVEL)...3063
EA-21 ERROR CODE [154] (ABNORMALITY IN INTAKE AIR TEMERATURE SENSOR SYSTEM LOW LEVEL)...3063
EA-22 ERROR CODE [221] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM HIGH LEVEL)...3064
EA-23 ERROR CODE [222] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM LOW)...3065
EA-24 ERROR CODE [234] (OVERSPEED)...3067
EA-25 ERROR CODE [254] (ABNORMALITY IN FUEL SHUT-OFF VALVE SYSTEM VOLTAGE)...3068
EA-26 ERROR CODE [259] (ABNORMALITY IN FUEL SHUT-OFF VALVE)...3069
EA-27 ERROR CODE [261] (ABNORMAL RISE IN FUEL TEMPERATURE)...3069
EA-28 ERROR CODE [263] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM HIGH LEVEL)...3070
EA-29 ERROR CODE [265] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM LOW LEVEL)...3070
EA-30 ERROR CODE [316] (ABNORMALITY IN FUEL PUMP ACTUATOR SYSTEM CURRENT)...3071
EA-31 ERROR CODE [318] (ABNORMALITY IN FUEL PUMP ACTUATOR)...3072
EA-32 ERROR CODE [343] (ABNORMALITY IN CONTROLLER INTERNAL COMMUNICATION)...3072
EA-33 ERROR CODE [346] (ABNORMALITY IN CONTROLLER POWER DOWN)...3073
EA-34 ERROR CODE [384] (ABNORMALITY IN PREHEATING HEATER CONTROL SYSTEM)...3074
EA-35 ERROR CODE [415] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 2))...3075
EA-36 ERROR CODE [423] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM IN RANGE)...3076
EA-37 ERROR CODE [431] (ABNORMALITY 1 IN IDLING VALIDATION SWITCH SYSTEM)...3078
EA-38 ERROR CODE [432] (IDLE VALIDATION PROCESS ERROR)...3080
EA-39 ERROR CODE [441] (ABNORMALITY IN BATTERY VOLTAGE LOW LEVEL)...3082
EA-40 ERROR CODE [442] (ABNORMALITY IN BATTERY VOLTAGE HIGH LEVEL)...3082
EA-41 ERROR CODE [451] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL)...3083
EA-42 ERROR CODE [452] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM LOW LEVEL)...3084
EA-43 ERROR CODE [455] (ABNORMALITY IN FUEL RAIL ACTUATOR SYSTEM CURRENT)...3085
EA-44 ERROR CODE [467] (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)...3086
EA-45 ERROR CODE [468] (ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL)...3086
EA-46 ERROR CODE [514] (ABNORMALITY IN FUEL RAIL ACTUATOR)...3086
EA-47 ERROR CODE [527] (ABNORMALITY IN DUAL OUTPUT SOLENOID A SYSTEM)...3087
EA-48 ERROR CODE [551] (ABNORMALITY 2 IN IDLE VALIDATION SWITCH SYSTEM)...3087
EA-49 ERROR CODE [554] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR IN RANGE)...3088
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)...3090
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR...3092
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN...3096
M-1 MAIN MONITOR DOES NOT WORK...3097
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY,ALL LAMPS STAY LIGHTED UP...3098
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY...3099
M-4 ABNORMALITY IN SHIFT INDICATOR...3100
a) DISPLAYS N EVEN WHEN DIRCETIONAL LEVER IS AT F...3100
b) DISPLAYS N EVEN WHEN DIRCETIONAL LEVER IS AT R...3100
c) DOES NOT DISPLAY N EVEN WHEN DIRCETIONAL LEVER IS AT N...3100
d) DOES NOT DISPLAY 1ST EVEN WHEN SPEED CONTROL LEVER IS AT 1ST...3101
e) DOES NOT DISPLAY 2ND EVEN WHEN SPEED CONTROL LEVER IS AT 2ND...3101
f) DOES NOT DISPLAY 3RD EVEN WHEN SPEED CONTROL LEVER IS AT 3RD...3101
g) DOES NOT DISPLAY 4TH EVEN WHEN SPEED CONTROL LEVER IS AT 4TH...3101
M-5 HIGH BEAM DISPLAY DOES NOT LIGHT UP...3103
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP...3104
a) L.H.TURN SIGNAL DISPLAY DOES NOT LIGHT UP...3104
b) R.H.TURN SIGNAL DISPLAY DOES NOT LIGHT UP...3104
M-7 ABNORMALITY IN PARKING LAMP DISPLAY...3105
a) PARKING LAMP DISPLAY DOES NOT LIGHT UP...3105
b) PARKING LAMP DISPLAY STAYS LIGHTED UP...3105
M-8 ABNORMALITY IN PREHEATING DISPLAY...3106
a) PREHEATIGN DISPLAY DOES NOT LIGHT UP...3106
b) PREHEATIGN DISPLAY STAYS LIGHTED UP...3106
M-9 NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP...3108
M-10 ABNORMALITY IN FRONT WORKING LAMP...3109
a) NEITHER MONITOR DISPLAY NOR FRONT WORKIGN LAMP LIGHT UP...3109
b) WORKIING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP...3109
c) MONITOR DISPLAY LIGHTS UP BUT WORKIGN LAMP DOES NOT LIGHT UP...3109
M-11 ABNORMALITY IN REAR WORKIGN LAMP...3111
a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP...3111
b) WORKIING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP...3111
c) MONITOR DISPLAY LIGHTS UP BUT WORKIGN LAMP DOES NOT LIGHT UP...3111
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF...3113
a) WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED,CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE...3113
b) WHEN TRANSMISSION CUT-OFF SWITCH IS TURNED OFF,CUT-OFF FUNCTION IS ALWAYS ACTUATED...3113
c) TRANSMISSION CUT-OFF SWITCH IS TURNED ON, BUT CUT-OFF FUNCTION IS NOT ACTUATED...3114
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNIGN...3115
a) WHEN PARKIGN BRAKE IS APPLIED,BUZZER SOUNDS INTERMITTENTLY AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AN N...3115
b) WHEN PARKIGN BRAKE IS APPLIED,BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRCETIONAL LEVER IS AT POSITION OTHER THAN N...3115
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY,OR THEY ARE NOT ACTUATED...3116
a) ACTUATED CONTINUOUSLY...3116
b) NOT ACTUATED...3116
M-15 ABNORMALITY IN BUZZER...3117
a) BUZZER DOES NOT SOUND FOR 3 SECONDS DURING SELF-CHECK WHEN STARTING SWITCH IS TURNED ON...3117
b) BUZZER ALWAYS SOUNDS...3117
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY...3118
M-17 ABNORMALITY IN FAILURE DISPLAY MODE...3119
a) FAILURE DISPLAY MODE DOES NOT WORK...3119
b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE...3119
M-18 ABNORMALITY IN EMERGENCY STEERING DISPLAY...3120
a) EMERGENCY STEERING DISPLAY DOES NOT FLASH...3120
b) EMERGENCY STEERING DISPLAY STAYS FLASHED...3120
M-19 ABNORMALITY IN AUTO-GREASING SYSTEM...3121
a) FORCED GREASING CANNOT BE CARRIED OUT ...3121
b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)...3121
c) WHEN NO MORE GREASE REMAINS,MONITOR DISPLAY FLASHES REPIDLY (2 TIMES/SEC)...3121
d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC)...3122
e) MONITOR DISPLAY GOES OUT ...3122
M-20 ABNORMALITY IN ECSS SYSTEM...3123
a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED...3123
b) MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK...3123
M-21 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)...3126
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)...3127
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR...3128
K-1 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SCONDS,MAINTENANCE MONITOR DOES NOT WORK...3132
a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP...3132
b) SOME LAMPS DO NOT LIGHT UP...3132
K-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT EVEN AFTER 3 SCONDS...3133
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTIGN SWITCH IS TURNED ON WITHIN 3 SECONDS,NO LAMPS ON MAINTENANCE MONITOR GO OUT...3134
K-4 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TRUNED ON,CHECK ITEM DISPLAY FLASHES...3135
a) ENGINE OIL LEVEL DISPLAY FLASHES...3135
b) ENGINE COOLANT LEVEL DISPLAY FLASHES...3136
K-5 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TRUNED ON,CAUTION ITEM DISPLAY FLASHES...3137
a) ENGINE OIL PRESSURE DISPLAY FLASHES...3137
b) BATTERY CHARGE DISPLAY FLASHES...3139
c) BRAKE OIL PRESSURE DISPLAY FLASHES...3140
d) AIR CLEANER CLOGGED DISPLAY FLASHES...3141
K-6 CAUTION ITEM DISPLAY IS FLASHING,BUT CAUTION BUZZER DOES NOT SOUND...3142
K-7 NO MONITOR DISPLAY LIGHTS UP,BUT CAUTION BUZZER SOUNDS...3143
K-8 CAUTION ITEM DISPLAY IS FLASHING,BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP DOES NOT FLASH...3144
a) CHECK LAMP...3144
b) CAUTION LAMP...3144
K-9 NO MAINTENANCE MONITOR DISPLAY LIGHTS UP,BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP LIGHTS UP...3145
a) CHECK LAMP...3145
b) CAUTION LAMP...3145
K-10 ONLY NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON...3146
K-11 NIGHT LIGHTING OF MONITOR LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF...3147
K-12 SERVICE METER DOES NOT WORK...3148
K-13 SERVICE METER IN RUNNING EVEN WHEN ENGINE IS STOPPED...3148
K-14 ABNORMALITY IN GAUGES...3149
a) ABNORMALITY IN FUEL GAUGE...3149
b) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE...3150
c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE...3151
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...3152
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,ENGINE STARTIGN,ENGINE STOPPING,APS SYSTEM...3154
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION AND PARKING BRAKE...3156
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN...3157
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER...3158
E-1 ENGINE DOES NOT START ...3159
a) STARTING MOTOR DOES NOT TURN...3159
b) STARTING MOTOR TURNS...3164
E-2 ENGINE DOES NOT STOP (SERIAL NO.:50001-52000)...3172
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING (SERIAL NO.:50001-52000)...3172
E-4A ABNORMALITY IN APS SYSTEM (SERIAL NO.:50001-52000)...3174
a) WHEN PREHEATING SWITCH IS TRUNED AUTO,PREHEATING LAMP DOES NOT LIGHT UP,BUT NO PILOT LED ON APS CONTROLLER LIGHTS UP...3176
b) WHEN PREHEATING SWITCH IS TRUNED AUTO AND ENGINE WATER TEMPERATURE IS BELOW 20℃,PREHEATING LAMP FLASHES,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL...3177
c) AFTER PREHEATING,FUEL IS NOT INJECTED FROM APS NOZZLE WHEN STARTING SWITCH IS TURNED START,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL...3178
d) LED 1 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...3179
e) LED 2 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...3179
f) LED 3 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...3180
g) LED 4 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...3180
h) LED 5 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...3181
i) LED 6 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...3181
j) WHEN PREHEATING SWITCH IS OFF,PREHEATING LAMP LIGHTS UP...3182
E-4B PREHEATING FAULT (SERIAL NO.:52001 AND UP)...3183
E-5 PARKING BRAKE DOES NOT HAVE EFFECT...3184
a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON...3184
b) PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE DROPS...3184
E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING...3185
E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON...3187
E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED,BUT PARKING BRAKE WORKS NORMALLY...3187
E-9 TRANSMISSION DOES NOT WORK PROPELY...3189
a) ABNORMALITY IN PARKING BRAKE CIRCUIT,TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY CIRCUIT...3190
b) NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT...3193
c) NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT...3195
d) SHORT CIRCUIT TO CHASSIS GROUND IN DIRCETIONAL SOLENOID CIRCUIT...3197
e) ABNORMALITY IN SHIFT SOLENOID CIRCUIT...3202
f) SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT...3205
E-10 KICK-DOWN SWITCH DOES NOT WORK...3210
E-11 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON...3213
E-12 KICK-DOWN ALWAYS WORKS...3214
E-13 KICK-DOWN SWITCH WORKS EVEN WHEN TRAVELING FORWARD IN 2ND...3216
E-14 BOOM KICK-OUT DOES NOT WORK...3218
E-15 DEFECTIVE BUCKET POSITIONER...3221
E-16 POWER WINDOW DOES NOT WORK...3224
a) POWER WINDOW DOES NOT RISE...3224
b) POWER WINDOW DOES NOT LOWER...3225
E-17 ABNORMALITY IN FRONT WORKING LAMP...3227
E-18 ABNORMALITY IN REAR WORKING LAMP...3227
E-19 ABNORMALITY IN TRANSMISSION CUT-OFF...3227
E-20 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING...3227
E-21 ABNORMALITY IN BUZZER...3227
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...3228
POWER TRAIN...3229
H-1 MACHINE DOES NOT START...3229
H-2 TRAVEL SPEED IS SLOW,OR LACKS POWER IN ALL SPEED RANGES...3230
H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR...3231
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH ...3232
STEERING SYSTEM...3233
H-5 STEERING WHEEL DOES NOT TURN...3233
H-6 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK]...3234
H-7 TURNING,RESPONSE OF STEERING IS POOR...3235
H-8 TURNING,RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK]...3236
H-9 STEERING IS HEAVY...3238
H-10 JOYSTICK IS HEAVY [MACHINE WITH JOYSTICK]...3238
H-11 STEERING WHEEL SHAKES OR JERKS...3239
H-12 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK [MACHINE WITH JOYSTICK]...3240
H-13 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING...3240
BRAKE SYSTEM...3241
H-14 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR...3241
H-15 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG...3243
H-16 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR...3244
H-17 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS (INCLUDING EMERGENCY RELEASE SYSTEM)...3245
WORK EQUIPMENT...3246
H-18 NEITHER LIFT ARM NOR BUCKET MOVE...3246
H-19 BOTH LIFT ARM AND BUCKET ARE SLOW OR LACK POWER...3247
H-20 LIFT ARM DOES NOT MOVE...3248
H-21 LIFT ARM DOES NOT MOVE [MACHINES WITH REMOTE BOOM CONTROL]...3249
H-22 LIFT ARM IS SLOW OR BOOM LACKS POWER...3250
H-23 LIFT ARM IS SLOW OR BOOM LACKS POWER [MACHINES WITH REMOTE BOOM CONTROL]...3251
H-24 LIFT ARM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT...3252
H-25 LIFT ARM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE...3252
H-26 REMOTE LIFT ARM CONTROL DOES NOT WORK [MACHINES WITH REMOTE BOOM CONTROL]...3253
H-27 EXCESSIVE HYDRAULIC DRIFT OF LIFT ARM...3254
H-28 BUCKET DOES NOT MOVE...3255
H-29 BUCKET IS SLOW OR LACKS POWER...3256
H-30 EXCESSIVE HYDRAULIC DRIFT OF BUCKET...3257
H-31 ECSS DOES NOT WORK, AND THERE IS PITCHING AND BOUNCING [MACHINES WITH ECSS]...3258
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE) (ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL)...3260
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE ...3261
JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM...3262
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS,AND PROBLEMS ON MACHINE...3263
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM...3267
T-1 FAILURE CODE [10] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN BACKUP LAMP RELAY)IS DISPLAYED...3271
T-2 FAILURE CODE [12] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN F SOLENOID)IS DISPLAYED...3272
T-3 FAILURE CODE [13] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN R SOLENOID)IS DISPLAYED...3273
T-4 FAILURE CODE [14] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 1ST SOLENOID)IS DISPLAYED...3274
T-5 FAILURE CODE [15] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 2ND SOLENOID)IS DISPLAYED...3275
T-6 FAILURE CODE [16] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 3RD SOLENOID)IS DISPLAYED...3276
T-7 FAILURE CODE [17] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 4TH SOLENOID)IS DISPLAYED...3277
T-8 FAILURE CODE [19] (SHORT CIRCUIT,DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM)IS DISPLAYED...3278
T-9 FAILURE CODE [20] (SHORT CIRCUIT,DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM)IS DISPLAYED...3279
T-10 FAILURE CODE [21] (SHORT CIRCUIT,DISCONNECTION IN SHIFT SWITCH SYSTEM)IS DISPLAYED...3283
T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM)IS DISPLAYED...3286
T-12 FAILURE CODE [23] (SHORT CIRCUIT,DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)IS DISPLAYED...3287
T-13 SHIFT-UP DOES NOT WORK...3289
T-14 SHIFT-DOWN DOES NOT WORK...3289
T-15 TRANSMISSION CUTOFF DOES NOT WORK OR STAYS WORKING...3290
T-16 NEUTRALIZER DOES NOT WORK OR STAYS WORKING...3291
T-17 BUZZER DOES NOT WORK...3292
T-18 ABNORMALITY IN NETWORK SYSTEM...3293
T-19 ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY...3294
T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM...3295
T-21 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS...3296
TROUBLESHOOTING OF JOYSTICK STEERING SYSTEM (J MODE) (ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL)...3297
JUDGEMENT TABLE FOR JOYSTICK CONTROL SYSTEM...3298
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...3299
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM...3303
J-1 FAILURE CODE [56] (SHORT CIRCUIT,OR DISCONNECTION IN CAUTION RELAY OUTPUT)IS DISPLAYED...3305
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT))IS DISPLAYED...3306
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT))IS DISPLAYED...3307
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE))IS DISPLAYED...3308
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE))IS DISPLAYED...3309
J-6 FAILURE CODE [61] (SHORT CIRCUIT,OR DISCONNECTION IN STEERING COLENOID CUT RELAY OUTPUT)IS DISPLAYED...3310
J-7 FAILURE CODE [62] (SHORT CIRCUIT,OR DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT)IS DISPLAYED...3311
J-8 FAILURE CODE [63] (SHORT CIRCUIT,OR DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER)IS DISPLAYED...3312
J-9 ABNORMALITY IN POWER SUPPLY,OR POWER SUPPLY VOLTAGE...3313
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT...3314
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID...3315
J-12 DISCONNECTION IN STEERING LEFT SOLENOID...3316
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE)...3317
ACTION TAKEN BY TRANSMISSION CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...3318
ELECTRICAL CIRCUIT DIAGRAM FOR ECSS...3322
D-1 ECSS DOES NOT WORK...3324
a) ERROR CODE [d0] IS DISPLAYED...3325
b) ERROR CODE [d1] IS DISPLAYED...3325
c) ERROR CODE [d2] IS DISPLAYED...3326
d) ERROR CODE [d3] IS DISPLAYED...3326
e) ERROR CODE [d4] IS DISPLAYED...3327
f) ERROR CODE [d5] IS DISPLAYED...3327
g) ERROR CODE [d6] IS DISPLAYED...3328
h) NO ABNORMALITY DISPLAY IS GIVEN...3331
D-2 ECSS CANNOT BE CANCELED...3337
30 DISASSEMBLY AND ASSEMBLY...3338
METHOD OF USING MANUAL...3340
PRECAUTIONS WHEN CARRYING OUT OPERATION...3341
SPECIAL TOOL LIST...3343
SKETCHES OF SPECIAL TOOLS...3352
STARTING MOTOR...3360
REMOVAL AND INSTALLATION...3360
ALTERNATOR...3361
REMOVAL AND INSTALLATION...3361
ENGINE OIL COOLER (SERIAL NO.:50001-52000)...3363
REMOVAL AND INSTALLATION...3363
FUEL INJECTION PUMP (SERIAL NO.:50001-52000)...3364
REMOVAL AND INSTALLATION...3364
WATER PUMP (SERIAL NO.:50001-52000)...3365
REMOVAL AND INSTALLATION...3365
NOZZLE HOLDER (SERIAL NO.:50001-52000)...3366
REMOVAL AND INSTALLATION...3366
TURBOCHARGER (SERIAL NO.:50001-52000)...3367
REMOVALL...3367
INSTALLATION...3368
ENGINE FRONT SEAL (SERIAL NO.:50001-52000)...3369
REPLACEMENT...3369
ENGINE REAR SEAL (SERIAL NO.:50001-52000)...3371
REPLACEMENT...3371
CYLINDER HEAD (SERIAL NO.:50001-52000)...3373
REMOVAL...3373
INSTALLATION...3378
THERMOSTAT (SERIAL NO.:50001-52000)...3380
REMOVAL AND INSTALLATION...3380
AFTERCOOLER CORE (SERIAL NO.:50001-52000)...3381
REMOVAL...3381
INSTALLATION...3382
RADIATOR...3383
REMOVAL...3383
INSTALLATION...3385
RADIATOR (WITH SUCTION FAN)...3390
REMOVAL...3390
INSTALLATION...3393
ENGINE AND TORQUE CONVERTER ASSEMBLY...3394
REMOVAL...3394
INSTALLATION...3396
TORQUE CONVERTER...3402
REMOVAL AND INSTALLATION...3402
DISASSEMBLY...3405
ASSEMBLY...3410
TRANSMISSION...3429
REMOVAL...3429
INSTALLATION...3431
DISASSEMBLY...3432
ASSEMBLY...3447
TRANSMISSION VALVE...3463
REMOVAL AND ASSEMBLY...3463
TRANSFER...3464
DISASSEMBLY...3464
ASSEMBLY...3473
CENTER SUPPORT...3484
REMOVAL AND INSTALLATION...3484
DISASSEMBLY...3486
ASSEMBLY...3487
DRIVE SHAFT...3490
DISASSEMBLY...3490
ASSEMBLY...3493
FRONT AXLE...3496
REMOVAL...3496
INSTALLATION...3497
FRONT DIFFERENTIAL...3498
REMOVAL...3498
INSTALLATION...3499
REAR AXLE...3500
REMOVAL...3500
INSTALLATION...3503
REAR DIFFERENTIAL...3504
REMOVAL...3504
INSTALLATION...3505
DIFFERENTIAL GEAR ...3506
DISASSEMBLY...3506
ASSEMBLY...3510
LIMITED SLIP DIFFERENTIAL...3518
DISASSEMBLY...3518
ASSEMBLY...3523
FINAL DRIVE...3544
REMOAL...3544
ASSEMBLY...3546
ORBIT-ROLL...3549
REMOVAL AND INSTALLATION...3549
STEERING CYLINFER...3550
REMOVAL...3550
INSTALLATION...3551
DISASSEMBLY...3552
ASSEMBLY...3554
STEERING VALVE...3556
REMOVAL...3556
INSTALLATION...3557
CUT-OFF VALVE...3558
REMOVAL AND INSTALLATION...3558
BRAKE VALVE...3559
REMOVAL AND INSTALLATION...3559
BRAKE VALVE (R.H.)...3560
DISASSEMBLY...3560
ASSEMBLY...3562
BRAKE VALVE (L.H.)...3564
DISASSEMBLY...3564
ASSEMBLY...3566
SLACK ADJUSTER...3568
REMOVAL AND INSTALLATION...3568
DISASSEMBLY...3569
ASSEMBLY...3570
BRAKE...3571
REMOVAL AND INSTALLATION...3571
DISASSEMBLY...3572
ASSEMBLY...3575
HYDRAULIC PUMP...3579
REMOVAL...3579
INSTALLATION...3580
HYDRAULIC TANK...3583
REMOVAL...3583
INSTALLATION...3584
HUDRAULIC FILTER...3585
REMOVAL AND INSTALLATION...3585
PPC VALVE...3586
REMOVAL AND INSTALLATION...3586
DISADDEMBLY AND ASSEMBLY...3587
WORK EQUIPMENT VALVE...3588
REMOVAL...3588
INSTALLATION...3589
MAIN CONTROL VALVE...3590
DISASSEMBLY...3590
ASSEMBLY...3593
DUMP CYLINDER...3596
REMOVAL...3596
INSTALLATION...3597
LIFT CYLINDER...3598
REMOVAL...3598
INSTALLATION...3599
LIFT DYLINDER AND DUMP CYLINDER...3600
DISASSEMBLY...3600
ASSEMBLY...3602
CENTER HINGE PIN...3605
REMOVAL...3605
INSTALLATION...3610
WORK EQUIPMENT...3613
REMOVAL...3613
INSTALLATION...3617
BULKHEAD...3619
REMOVAL...3619
INSTALLATION...3620
FLOOR FRAME...3621
REMOVAL...3621
INSTALLATION...3623
COUNTERWEIGHT...3624
REMOVAL AND INSTALLATION...3624
FUEL TANK...3625
REMOVAL...3625
INSTALLATION...3626
CAB...3629
REMOVAL...3629
INSTALLATION...3631
STOP VALVE...3632
REMOVAL AND INSTALLATION...3632
ACCUMULATOR...3633
REMOVAL AND INSTALLATION...3633
ASSUMULATOR CHARGR VALVE...3634
REMOVAL AND INTALLATION...3634
PARKING BRAKE SOLENOID VALVE...3635
REMOVAL AND SINTALLATION...3635
DIVERTER VALVE...3636
REMOVAL AND INSTALLATION...3636
EMERGENCY STEERING PUMP...3637
REMOVAL AND INSTALLATION...3637
PARKING BRAKE...3638
REMOVAL AND INSTALLATION...3638
PARKING BRAKE CALIPERS...3639
DISASSEMBLY...3639
ASSEMBLY...3640
PARKING BRAKE PAD...3641
REMOVAL AND INSTALLATION...3641
REAR TIRES...3642
REMOVAL AND INSTALLATION...3642
AIR CONDITIONER COMPRESSOR...3643
REMOVAL...3643
INSTALLATION...3644
AIR CONDITIONER CONDENSER...3645
REMOVAL AND INSTALLATION...3645
RECEIVER TANK...3646
REMOVAL AND INSTALLATION...3646
AIR CONDITIONER UNIT...3647
REMOVAL...3647
INSTALLATION...3648
MONITOR...3649
REMOVAL AND INSTALLATION...3649
40 MAINTENANCE STANDARD...3650
ENGINE MOUNT...3651
TRANSMISSION MOUNT...3653
TORQUE CONVERTER ...3655
TORQUE CONVERTER REGULATOR VALVE (SERIAL NO.:52001 AND UP)...3658
TRANSMISSION...3659
TRANSFER...3662
TRANSMISSION CONTROL VALVE...3664
DRIVE SHAFT...3669
CENTER SUPPORT...3670
DIFFERENTIAL...3671
LIMITED SLIP DIFFERENTIAL (IF EQUIPPED)...3675
FINAL DRIVE...3679
AXLE MOUNT...3683
STEERING COLUMN...3687
STEERING VLAVE...3688
EMERGENCY STEERING PUMP...3689
DIVERTER VALVE...3690
STEERING CYLINDER MOUNT...3691
BRAKE VALVE...3692
SLACK ADJUSTER...3698
BRAKE...3700
PARKING BRAKE...3704
HYDRAULIC PUMP...3705
PPC VALVE...3710
CUT-OFF VALVE...3712
MAIN CONTROL VALVE...3713
HYDRAULIC CYLINDER...3715
WORK EQUIPMENT LINKAGE...3717
BUCKET...3719
BUCKET POSITIONER AND BOOM KICK-OUT...3720
ROPS CANOPY...3722
90 OTHERS...3723
FOR STANDARD MACHINE (SERIAL NO.:50001-52000)...3724
ELECTRIC CIRCUIT DIAGRAM (1/4)...3724
ELECTRIC CIRCUIT DIAGRAM (2/4)...3725
ELECTRIC CIRCUIT DIAGRAM (3/4)...3726
ELECTRIC CIRCUIT DIAGRAM (4/4)...3727
FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL (SERIAL NO.50001-52000)...3728
ELECTRIC CIRCUIT DIAGRAM (1/4)...3728
ELECTRIC CIRCUIT DIAGRAM (2/4)...3729
ELECTRIC CIRCUIT DIAGRAM (3/4)...3730
ELECTRIC CIRCUIT DIAGRAM (4/4)...3731
FOR STANKARD MACHINE (SERIAL NO.52001 AND UP)...3732
ELECTRIC CIRCUIT DIAGAM (1/5)...3732
ELECTRIC CIRCUIT DIAGAM (2/5)...3733
ELECTRIC CIRCUIT DIAGAM (3/5)...3734
ELECTRIC CIRCUIT DIAGAM (4/5)...3735
ELECTRIC CIRCUIT DIAGAM (5/5)...3736
FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL (SERIAL NO.52001 AND UP)...3737
ELECTRIC CIRCUIT DIAGRAM (1/3)...3737
ELECTRIC CIRCUIT DIAGRAM (2/3)...3738
ELECTRIC CIRCUIT DIAGRAM (3/3)...3739
SEBM013218 - Wheel Loader WA600-3 avance Shop Manual...3740
COVER...3740
CONTENTS...3741
01 GENERAL...3768
GENERAL ASSEMBLY DRAWING...3769
SPECIFICATIONS...3774
WEIGHT TABLE...3780
LIST OF LUBRICANT AND COOLANT...3783
10 STRUCTURE AND FUNCTION...3785
POWER TRAIN...3786
POWER TRAIN SYSTEM...3787
RADIATOR,HYDRAULIC OIL COOLER...3791
RADIATOR, HYDRAULIC OIL COOLER (WITH SUCTION FAN)...3794
TORQUE CONVERTER AND TRANSMISSION PIPING...3796
HYDRAULIC CIRCUIT FOR POWER TRAIN...3798
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN...3800
TORQUE CONVERTER...3804
TORQUE CONVERTER REGULATOR VALVE (SERIAL NO.:52001 AND UP)...3810
TRANSMISSION...3812
TRANSMISSION CONTROL VALVE...3821
TORQUE CONVERTER OIL COOLER...3841
TORQUE CONVERTER OIL FILTER...3842
TRANSFER...3844
DRIVE SHAFT...3845
CENTER SUPPORT...3846
AXLE...3847
DIFFERENTIAL...3849
LIMITED SLIP DIFFERENTIAL(OP)...3852
FINAL DRIVE...3856
AXLE MOUNT...3859
CENTER HINGE PIN...3861
STEERING PIPING...3862
STEERING COLUMN...3865
STEERING UNIT (ORBIT-ROLL VAVLE)...3866
STEERING VALVE...3869
TWO-WAY RESTRICTION VALVE...3880
STOP VALVE...3881
EMERGENCY STEERING PIPING...3882
DIVERTER VALVE (FOR EMERGENCY STEERING)...3883
BRAKE PIPING...3886
BRAKE CIRCUIT DIAGRAM...3890
BRAKE VALVE...3894
CHARGE VALVE...3901
ACCUMULATOR (FOR BRAKE)...3905
SLACK ADJUSTER...3906
BRAKE...3910
PARKING BRAKE...3913
SPRING CYLINDER...3915
PARKING BRAKE SOLENOID VALVE...3916
HYDRAULIC PIPING...3917
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...3921
WORK EQUIPMENT LEVER LINKAGE...3927
HYDRAULIC TANK...3928
ACCUMULATOR (FOR PPC VALVE)...3930
PPC VALVE...3931
PPC RELIEF VALVE...3935
CUT-OFF VALVE...3936
MAIN CONTROL VALVE...3938
AUTO GREASE SYSTEM...3952
LUBRICATION OF WORK EQUIPMENT...3964
WORK EQUIPMENT LINKAGE...3966
BUCKET...3968
BUCKET POSITIONER AND BOOM KICK-OUT...3969
OPERATION OF PROXIMITY SWITCH...3972
ROPS CANOPY...3976
CAB...3977
CAR HEATER...3978
AIR CONDITIONER...3980
ELECTRIC CIRCUIT DIAGRAM...3984
MACHINE MONITOR SYSTEM...3989
MAIN MONITOR...3991
MANITENANCE MONITOR...3995
MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL...3997
ENGINE STARTING CIRCUIT...4013
ENGINE STOP CIRCUIT...4016
AUTO PRIMING SYSTEM (APS) (SERIAL NO.:50001-52000)...4018
PRE-HEATING CIRCUIT (SERIAL NO.:52001 AND UP)...4022
ELECTRIC TRANSMISSION CONTROL...4023
KICK-DOWN,HOLD SWITCH...4026
KICK-DOWN ELECTRICAL CIRCUIT...4027
ELECTRIC PARKING BRAKE CONTROL...4033
E.C.S.S.(ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)...4042
20 TESTING AND ADJUSTING...4056
STANDARD VALUE TABLE FOR ENGINE...4057
STANDARD VALUE TABLE FOR CHASSIS...4059
STANDARD VALUE TABLE FOR ELECTRICAL PARTS...4069
TESTING AND ADJUSTING...4082
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...4083
MEASURING ENGINE SPEED...4086
MEASURING EXHAUST GAS COLOR...4090
ADJUSTING VALVE CLEARANCE...4091
TESTING AND ADJUSTING INJECTOR LIFT (SERIAL NO.:52001 AND UP)...4093
MEASURING COMPRESSION PRESSURE...4095
MEASURING BLOW-BY PRESSURE...4098
MEASURING ENGINE OIL PRESSURE...4099
TESTING AND ADJUSTING FUEL INJECTON TIMING (SERIAL NO.:50001-52000)...4100
REPLACING FAN BELT ADJUSTING AUTO-TENSIONER...4102
TESTING AND ADJUSTING ALTERNATOR BELT TENSION...4103
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR...4104
HANDLING EQUIPMENT IN FUEL CIRCUIT (SERIAL NO.:52001 AND UP)...4105
MEASURING FUEL PUMP OUTPUT PORT PRESSURE (SERIAL NO.:52001 AND UP)...4105
BLEEDING AIR FROM FUEL CIRCUIT (SERIAL NO.:52001 AND UP)...4106
MEASURING EXHAUST TEMPERATURE...4108
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)...4111
ADJUSTING SPEED SENSOR...4112
ADJUSTIN FUEL CONTROL CABLE (SERIAL NO.:50001-52000)...4113
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE (SERIAL NO.:50001-52000)...4114
TESTING AND ADJUSTING TORQUE CONVERTER,TRANSMISSION OIL PRESSURE...4116
PROCEDURE FOR FLUSHING TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT...4125
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS...4126
TESTING AND ADJUSTING STEERING OIL PRESSURE...4130
TESTING AND ADJUSTING STEERING STOP VALVE...4132
TESTING BRAKE OIL PRESSURE...4133
MEASURING WEAR OF BRAKE DISC...4134
MEASURING BRAKE PERFORMANCE...4135
TESTING AND ADJUSTING PARKING BRAKE...4136
TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE...4138
TESTING AND ADJUSTING PPC OIL PRESSURE...4139
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE...4141
ADJUSTING WORK EQUIPMENT LEVER LINKAGE...4143
TESTING AND ADJUSTING OF BUCKET POSITIONER...4145
TESTING AND ADJUSTING OF BOOM KICK-OUT...4146
TESTING PROXIMITY SWITCH ACTUATION PILOT LAMP...4147
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)...4148
BLEEDING AIR...4149
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...4150
TROUBLESHOOTING...4153
POINTS TO REMEMBER WHEN TROUBLESHOOTING...4154
SEQUENCE OF EVENTS IN TROUBLESHOOTING...4155
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...4156
CHECKS BEFORE TROUBLESHOOTING...4164
CONNECTOR TYPES AND MOUNTING LOCATIONS...4165
CONNECTOR ARRANGEMENT DIAGRAM...4168
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...4180
METHOD OF USING TROUBLESHOOTING CHARTS...4201
METHOD OF USING MATRIX TROUBLESHOOTING TABLES...4203
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...4205
METHOD OF USING TROUBLESHOOTING CHART...4206
S-1 STARTING PERFORMANCE IS POOR (STARING ALWAYS TAKES TIME)...4210
S-2 ENGINE DOES NOT START...4212
(1) ENGINE DOES NOT TURN...4212
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...4213
(3) EXHAUST GAS SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...4214
S-3 ENGINE DOES NOT PICK-UP SMOOTHLY (FOLLOW-UP IS POOR)...4215
S-4 ENGINE STOPS DURING OPERATIONS...4216
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...4217
S-6 ENGINE LACKS OUTPUT...4218
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...4219
S-8 OIL COMSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...4220
S-9 OIL BECOMES CONTAMINATED QUICKLY...4221
S-10 FUEL CONSUMPTION IS EXCESSIVE...4222
S-11 OIL IS COOLING, OR COOLANT SPURTS BACK,OR COOLANT LEVEL GOES DOWN...4223
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)...4224
S-13 OIL LEVEL RISES...4225
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...4226
S-15 ABNORMAL NOISE IS MADE...4227
S-16 VIBRATION IS EXCESSIVE...4228
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (EA MODE)...4229
METHOD OF ERROR CODE DISPLAY...4231
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED...4233
SCHEMATIC DIAGRAM FOR ENGINE CONTROL SYSTEM...4241
EA-1 ERROR CODE [111] (ABNORMALITY IN CONTROLLER MEMORY)...4243
EA-2 ERROR CODE [112] (ABNORMALITY IN TIMING RAIL ACTUATOR)...4243
EA-3 ERROR CODE [113] (ABNORMALITY WITH ELECTRIC CURRENT IN TIMING RAIL ACTUATOR SYSTEM)...4244
EA-4 ERROR CODE [115] (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEM)...4245
EA-5 ERROR CODE [116] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL)...4247
EA-6 ERROR CODE [117] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM LOW LEVEL)...4248
EA-7 ERROR CODE [118] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM HIGH LEVEL)...4249
EA-8 ERROR CODE [119] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM LOW LEVEL)...4250
EA-9 ERROR CODE [121] (ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEM)...4251
EA-10 ERROR CODE [122] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM HIGH LEVEL)...4252
EA-11 ERROR CODE [123] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM LOW LEVEL)...4253
EA-12 ERROR CODE [131] (ABNORMALITY IN ACCELERATOR SENSOR SYSTEM HIGH LEVEL)...4254
EA-13 ERROR CODE [132] (ABNORMALITY IN ACCELERATOR SENSOR SYSTEM LOW LEVEL)...4255
EA-14 ERROR CODE [135] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM HIHG LEVEL)...4256
EA-15 ERROR CODE [141] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM LOW LEVEL)...4257
EA-16 ERROR CODE [143] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 1))...4258
EA-17 ERROR CODE [144] (ABNORMALITY IN COOLANT TEMPERATURE SENSOR SYSTEM HIGH LEVEL)...4259
EA-18 ERROR CODE [145] (ABNORMALITY IN COOLANT TEMPERATURE SENSOR SYSTEM LOW LEVEL)...4260
EA-19 ERROR CODE [151] (ABNORMALITY RISE IN WATER TEMPERATURE)...4260
EA-20 ERROR CODE [153] (ABNORMALITY IN INTAKE AIR TEMPERATURE SENSOR SYSTEM HIGH LEVEL)...4261
EA-21 ERROR CODE [154] (ABNORMALITY IN INTAKE AIR TEMERATURE SENSOR SYSTEM LOW LEVEL)...4261
EA-22 ERROR CODE [221] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM HIGH LEVEL)...4262
EA-23 ERROR CODE [222] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM LOW)...4263
EA-24 ERROR CODE [234] (OVERSPEED)...4265
EA-25 ERROR CODE [254] (ABNORMALITY IN FUEL SHUT-OFF VALVE SYSTEM VOLTAGE)...4266
EA-26 ERROR CODE [259] (ABNORMALITY IN FUEL SHUT-OFF VALVE)...4267
EA-27 ERROR CODE [261] (ABNORMAL RISE IN FUEL TEMPERATURE)...4267
EA-28 ERROR CODE [263] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM HIGH LEVEL)...4268
EA-29 ERROR CODE [265] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM LOW LEVEL)...4268
EA-30 ERROR CODE [316] (ABNORMALITY IN FUEL PUMP ACTUATOR SYSTEM CURRENT)...4269
EA-31 ERROR CODE [318] (ABNORMALITY IN FUEL PUMP ACTUATOR)...4270
EA-32 ERROR CODE [343] (ABNORMALITY IN CONTROLLER INTERNAL COMMUNICATION)...4270
EA-33 ERROR CODE [346] (ABNORMALITY IN CONTROLLER POWER DOWN)...4271
EA-34 ERROR CODE [384] (ABNORMALITY IN PREHEATING HEATER CONTROL SYSTEM)...4272
EA-35 ERROR CODE [415] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 2))...4273
EA-36 ERROR CODE [423] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM IN RANGE)...4274
EA-37 ERROR CODE [431] (ABNORMALITY 1 IN IDLING VALIDATION SWITCH SYSTEM)...4276
EA-38 ERROR CODE [432] (IDLE VALIDATION PROCESS ERROR)...4278
EA-39 ERROR CODE [441] (ABNORMALITY IN BATTERY VOLTAGE LOW LEVEL)...4280
EA-40 ERROR CODE [442] (ABNORMALITY IN BATTERY VOLTAGE HIGH LEVEL)...4280
EA-41 ERROR CODE [451] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL)...4281
EA-42 ERROR CODE [452] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM LOW LEVEL)...4282
EA-43 ERROR CODE [455] (ABNORMALITY IN FUEL RAIL ACTUATOR SYSTEM CURRENT)...4283
EA-44 ERROR CODE [467] (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)...4284
EA-45 ERROR CODE [468] (ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL)...4284
EA-46 ERROR CODE [514] (ABNORMALITY IN FUEL RAIL ACTUATOR)...4284
EA-47 ERROR CODE [527] (ABNORMALITY IN DUAL OUTPUT SOLENOID A SYSTEM)...4285
EA-48 ERROR CODE [551] (ABNORMALITY 2 IN IDLE VALIDATION SWITCH SYSTEM)...4285
EA-49 ERROR CODE [554] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR IN RANGE)...4286
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)...4288
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR...4290
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN...4294
M-1 MAIN MONITOR DOES NOT WORK...4295
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY,ALL LAMPS STAY LIGHTED UP...4296
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY...4297
M-4 ABNORMALITY IN SHIFT INDICATOR...4298
a) DISPLAYS N EVEN WHEN DIRCETIONAL LEVER IS AT F...4298
b) DISPLAYS N EVEN WHEN DIRCETIONAL LEVER IS AT R...4298
c) DOES NOT DISPLAY N EVEN WHEN DIRCETIONAL LEVER IS AT N...4298
d) DOES NOT DISPLAY 1ST EVEN WHEN SPEED CONTROL LEVER IS AT 1ST...4299
e) DOES NOT DISPLAY 2ND EVEN WHEN SPEED CONTROL LEVER IS AT 2ND...4299
f) DOES NOT DISPLAY 3RD EVEN WHEN SPEED CONTROL LEVER IS AT 3RD...4299
g) DOES NOT DISPLAY 4TH EVEN WHEN SPEED CONTROL LEVER IS AT 4TH...4299
M-5 HIGH BEAM DISPLAY DOES NOT LIGHT UP...4301
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP...4302
a) L.H.TURN SIGNAL DISPLAY DOES NOT LIGHT UP...4302
b) R.H.TURN SIGNAL DISPLAY DOES NOT LIGHT UP...4302
M-7 ABNORMALITY IN PARKING LAMP DISPLAY...4303
a) PARKING LAMP DISPLAY DOES NOT LIGHT UP...4303
b) PARKING LAMP DISPLAY STAYS LIGHTED UP...4303
M-8 ABNORMALITY IN PREHEATING DISPLAY...4304
a) PREHEATIGN DISPLAY DOES NOT LIGHT UP...4304
b) PREHEATIGN DISPLAY STAYS LIGHTED UP...4304
M-9 NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP...4306
M-10 ABNORMALITY IN FRONT WORKING LAMP...4307
a) NEITHER MONITOR DISPLAY NOR FRONT WORKIGN LAMP LIGHT UP...4307
b) WORKIING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP...4307
c) MONITOR DISPLAY LIGHTS UP BUT WORKIGN LAMP DOES NOT LIGHT UP...4307
M-11 ABNORMALITY IN REAR WORKIGN LAMP...4309
a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP...4309
b) WORKIING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP...4309
c) MONITOR DISPLAY LIGHTS UP BUT WORKIGN LAMP DOES NOT LIGHT UP...4309
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF...4311
a) WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED,CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE...4311
b) WHEN TRANSMISSION CUT-OFF SWITCH IS TURNED OFF,CUT-OFF FUNCTION IS ALWAYS ACTUATED...4311
c) TRANSMISSION CUT-OFF SWITCH IS TURNED ON, BUT CUT-OFF FUNCTION IS NOT ACTUATED...4312
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNIGN...4313
a) WHEN PARKIGN BRAKE IS APPLIED,BUZZER SOUNDS INTERMITTENTLY AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AN N...4313
b) WHEN PARKIGN BRAKE IS APPLIED,BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRCETIONAL LEVER IS AT POSITION OTHER THAN N...4313
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY,OR THEY ARE NOT ACTUATED...4314
a) ACTUATED CONTINUOUSLY...4314
b) NOT ACTUATED...4314
M-15 ABNORMALITY IN BUZZER...4315
a) BUZZER DOES NOT SOUND FOR 3 SECONDS DURING SELF-CHECK WHEN STARTING SWITCH IS TURNED ON...4315
b) BUZZER ALWAYS SOUNDS...4315
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY...4316
M-17 ABNORMALITY IN FAILURE DISPLAY MODE...4317
a) FAILURE DISPLAY MODE DOES NOT WORK...4317
b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE...4317
M-18 ABNORMALITY IN EMERGENCY STEERING DISPLAY...4318
a) EMERGENCY STEERING DISPLAY DOES NOT FLASH...4318
b) EMERGENCY STEERING DISPLAY STAYS FLASHED...4318
M-19 ABNORMALITY IN AUTO-GREASING SYSTEM...4319
a) FORCED GREASING CANNOT BE CARRIED OUT ...4319
b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)...4319
c) WHEN NO MORE GREASE REMAINS,MONITOR DISPLAY FLASHES REPIDLY (2 TIMES/SEC)...4319
d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC)...4320
e) MONITOR DISPLAY GOES OUT ...4320
M-20 ABNORMALITY IN ECSS SYSTEM...4321
a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED...4321
b) MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK...4321
M-21 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)...4324
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)...4325
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR...4326
K-1 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SCONDS,MAINTENANCE MONITOR DOES NOT WORK...4330
a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP...4330
b) SOME LAMPS DO NOT LIGHT UP...4330
K-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT EVEN AFTER 3 SCONDS...4331
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTIGN SWITCH IS TURNED ON WITHIN 3 SECONDS,NO LAMPS ON MAINTENANCE MONITOR GO OUT...4332
K-4 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TRUNED ON,CHECK ITEM DISPLAY FLASHES...4333
a) ENGINE OIL LEVEL DISPLAY FLASHES...4333
b) ENGINE COOLANT LEVEL DISPLAY FLASHES...4334
K-5 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TRUNED ON,CAUTION ITEM DISPLAY FLASHES...4335
a) ENGINE OIL PRESSURE DISPLAY FLASHES...4335
b) BATTERY CHARGE DISPLAY FLASHES...4337
c) BRAKE OIL PRESSURE DISPLAY FLASHES...4338
d) AIR CLEANER CLOGGED DISPLAY FLASHES...4339
K-6 CAUTION ITEM DISPLAY IS FLASHING,BUT CAUTION BUZZER DOES NOT SOUND...4340
K-7 NO MONITOR DISPLAY LIGHTS UP,BUT CAUTION BUZZER SOUNDS...4341
K-8 CAUTION ITEM DISPLAY IS FLASHING,BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP DOES NOT FLASH...4342
a) CHECK LAMP...4342
b) CAUTION LAMP...4342
K-9 NO MAINTENANCE MONITOR DISPLAY LIGHTS UP,BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP LIGHTS UP...4343
a) CHECK LAMP...4343
b) CAUTION LAMP...4343
K-10 ONLY NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON...4344
K-11 NIGHT LIGHTING OF MONITOR LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF...4345
K-12 SERVICE METER DOES NOT WORK...4346
K-13 SERVICE METER IN RUNNING EVEN WHEN ENGINE IS STOPPED...4346
K-14 ABNORMALITY IN GAUGES...4347
a) ABNORMALITY IN FUEL GAUGE...4347
b) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE...4348
c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE...4349
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...4350
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,ENGINE STARTIGN,ENGINE STOPPING,APS SYSTEM...4352
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION AND PARKING BRAKE...4354
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN...4355
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER...4356
E-1 ENGINE DOES NOT START ...4357
a) STARTING MOTOR DOES NOT TURN...4357
b) STARTING MOTOR TURNS...4362
E-2 ENGINE DOES NOT STOP (SERIAL NO.:50001-52000)...4370
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING (SERIAL NO.:50001-52000)...4370
E-4A ABNORMALITY IN APS SYSTEM (SERIAL NO.:50001-52000)...4372
a) WHEN PREHEATING SWITCH IS TRUNED AUTO,PREHEATING LAMP DOES NOT LIGHT UP,BUT NO PILOT LED ON APS CONTROLLER LIGHTS UP...4374
b) WHEN PREHEATING SWITCH IS TRUNED AUTO AND ENGINE WATER TEMPERATURE IS BELOW 20℃,PREHEATING LAMP FLASHES,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL...4375
c) AFTER PREHEATING,FUEL IS NOT INJECTED FROM APS NOZZLE WHEN STARTING SWITCH IS TURNED START,BUT PILOT LED ON APS CONTROLLER SHOWS NORMAL...4376
d) LED 1 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...4377
e) LED 2 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...4377
f) LED 3 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...4378
g) LED 4 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...4378
h) LED 5 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...4379
i) LED 6 OF PILOT LED ON APS CONTROLLER SHOWS ABNORMAL...4379
j) WHEN PREHEATING SWITCH IS OFF,PREHEATING LAMP LIGHTS UP...4380
E-4B PREHEATING FAULT (SERIAL NO.:52001 AND UP)...4381
E-5 PARKING BRAKE DOES NOT HAVE EFFECT...4382
a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON...4382
b) PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE DROPS...4382
E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING...4383
E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON...4385
E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED,BUT PARKING BRAKE WORKS NORMALLY...4385
E-9 TRANSMISSION DOES NOT WORK PROPELY...4387
a) ABNORMALITY IN PARKING BRAKE CIRCUIT,TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY CIRCUIT...4388
b) NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT...4391
c) NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT...4393
d) SHORT CIRCUIT TO CHASSIS GROUND IN DIRCETIONAL SOLENOID CIRCUIT...4395
e) ABNORMALITY IN SHIFT SOLENOID CIRCUIT...4400
f) SHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT...4403
E-10 KICK-DOWN SWITCH DOES NOT WORK...4408
E-11 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS BEING TURNED ON...4411
E-12 KICK-DOWN ALWAYS WORKS...4412
E-13 KICK-DOWN SWITCH WORKS EVEN WHEN TRAVELING FORWARD IN 2ND...4414
E-14 BOOM KICK-OUT DOES NOT WORK...4416
E-15 DEFECTIVE BUCKET POSITIONER...4419
E-16 POWER WINDOW DOES NOT WORK...4422
a) POWER WINDOW DOES NOT RISE...4422
b) POWER WINDOW DOES NOT LOWER...4423
E-17 ABNORMALITY IN FRONT WORKING LAMP...4425
E-18 ABNORMALITY IN REAR WORKING LAMP...4425
E-19 ABNORMALITY IN TRANSMISSION CUT-OFF...4425
E-20 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING...4425
E-21 ABNORMALITY IN BUZZER...4425
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...4426
POWER TRAIN...4427
H-1 MACHINE DOES NOT START...4427
H-2 TRAVEL SPEED IS SLOW,OR LACKS POWER IN ALL SPEED RANGES...4428
H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR...4429
H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH ...4430
STEERING SYSTEM...4431
H-5 STEERING WHEEL DOES NOT TURN...4431
H-6 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK]...4432
H-7 TURNING,RESPONSE OF STEERING IS POOR...4433
H-8 TURNING,RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK]...4434
H-9 STEERING IS HEAVY...4436
H-10 JOYSTICK IS HEAVY [MACHINE WITH JOYSTICK]...4436
H-11 STEERING WHEEL SHAKES OR JERKS...4437
H-12 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK [MACHINE WITH JOYSTICK]...4438
H-13 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING...4438
BRAKE SYSTEM...4439
H-14 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR...4439
H-15 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG...4441
H-16 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR...4442
H-17 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS (INCLUDING EMERGENCY RELEASE SYSTEM)...4443
WORK EQUIPMENT...4444
H-18 NEITHER LIFT ARM NOR BUCKET MOVE...4444
H-19 BOTH LIFT ARM AND BUCKET ARE SLOW OR LACK POWER...4445
H-20 LIFT ARM DOES NOT MOVE...4446
H-21 LIFT ARM DOES NOT MOVE [MACHINES WITH REMOTE BOOM CONTROL]...4447
H-22 LIFT ARM IS SLOW OR BOOM LACKS POWER...4448
H-23 LIFT ARM IS SLOW OR BOOM LACKS POWER [MACHINES WITH REMOTE BOOM CONTROL]...4449
H-24 LIFT ARM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT...4450
H-25 LIFT ARM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE...4450
H-26 REMOTE LIFT ARM CONTROL DOES NOT WORK [MACHINES WITH REMOTE BOOM CONTROL]...4451
H-27 EXCESSIVE HYDRAULIC DRIFT OF LIFT ARM...4452
H-28 BUCKET DOES NOT MOVE...4453
H-29 BUCKET IS SLOW OR LACKS POWER...4454
H-30 EXCESSIVE HYDRAULIC DRIFT OF BUCKET...4455
H-31 ECSS DOES NOT WORK, AND THERE IS PITCHING AND BOUNCING [MACHINES WITH ECSS]...4456
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE) (ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL)...4458
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE ...4459
JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM...4460
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS,AND PROBLEMS ON MACHINE...4461
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM...4465
T-1 FAILURE CODE [10] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN BACKUP LAMP RELAY)IS DISPLAYED...4469
T-2 FAILURE CODE [12] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN F SOLENOID)IS DISPLAYED...4470
T-3 FAILURE CODE [13] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN R SOLENOID)IS DISPLAYED...4471
T-4 FAILURE CODE [14] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 1ST SOLENOID)IS DISPLAYED...4472
T-5 FAILURE CODE [15] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 2ND SOLENOID)IS DISPLAYED...4473
T-6 FAILURE CODE [16] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 3RD SOLENOID)IS DISPLAYED...4474
T-7 FAILURE CODE [17] (SHORT CIRCUIT,DISCONNECTION,OR SHORT CIRCUIT WITH POWER SUPPLY IN 4TH SOLENOID)IS DISPLAYED...4475
T-8 FAILURE CODE [19] (SHORT CIRCUIT,DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM)IS DISPLAYED...4476
T-9 FAILURE CODE [20] (SHORT CIRCUIT,DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM)IS DISPLAYED...4477
T-10 FAILURE CODE [21] (SHORT CIRCUIT,DISCONNECTION IN SHIFT SWITCH SYSTEM)IS DISPLAYED...4481
T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM)IS DISPLAYED...4484
T-12 FAILURE CODE [23] (SHORT CIRCUIT,DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)IS DISPLAYED...4485
T-13 SHIFT-UP DOES NOT WORK...4487
T-14 SHIFT-DOWN DOES NOT WORK...4487
T-15 TRANSMISSION CUTOFF DOES NOT WORK OR STAYS WORKING...4488
T-16 NEUTRALIZER DOES NOT WORK OR STAYS WORKING...4489
T-17 BUZZER DOES NOT WORK...4490
T-18 ABNORMALITY IN NETWORK SYSTEM...4491
T-19 ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY...4492
T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM...4493
T-21 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS...4494
TROUBLESHOOTING OF JOYSTICK STEERING SYSTEM (J MODE) (ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL)...4495
JUDGEMENT TABLE FOR JOYSTICK CONTROL SYSTEM...4496
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...4497
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM...4501
J-1 FAILURE CODE [56] (SHORT CIRCUIT,OR DISCONNECTION IN CAUTION RELAY OUTPUT)IS DISPLAYED...4503
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT))IS DISPLAYED...4504
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT))IS DISPLAYED...4505
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE))IS DISPLAYED...4506
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE))IS DISPLAYED...4507
J-6 FAILURE CODE [61] (SHORT CIRCUIT,OR DISCONNECTION IN STEERING COLENOID CUT RELAY OUTPUT)IS DISPLAYED...4508
J-7 FAILURE CODE [62] (SHORT CIRCUIT,OR DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT)IS DISPLAYED...4509
J-8 FAILURE CODE [63] (SHORT CIRCUIT,OR DISCONNECTION IN JOYSTICK STEERING LEVER POTENTIOMETER)IS DISPLAYED...4510
J-9 ABNORMALITY IN POWER SUPPLY,OR POWER SUPPLY VOLTAGE...4511
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT...4512
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID...4513
J-12 DISCONNECTION IN STEERING LEFT SOLENOID...4514
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE)...4515
ACTION TAKEN BY TRANSMISSION CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...4516
ELECTRICAL CIRCUIT DIAGRAM FOR ECSS...4520
D-1 ECSS DOES NOT WORK...4522
a) ERROR CODE [d0] IS DISPLAYED...4523
b) ERROR CODE [d1] IS DISPLAYED...4523
c) ERROR CODE [d2] IS DISPLAYED...4524
d) ERROR CODE [d3] IS DISPLAYED...4524
e) ERROR CODE [d4] IS DISPLAYED...4525
f) ERROR CODE [d5] IS DISPLAYED...4525
g) ERROR CODE [d6] IS DISPLAYED...4526
h) NO ABNORMALITY DISPLAY IS GIVEN...4529
D-2 ECSS CANNOT BE CANCELED...4535
30 DISASSEMBLY AND ASSEMBLY...4536
METHOD OF USING MANUAL...4538
PRECAUTIONS WHEN CARRYING OUT OPERATION...4539
SPECIAL TOOL LIST...4541
SKETCHES OF SPECIAL TOOLS...4550
STARTING MOTOR...4560
REMOVAL AND INSTALLATION...4560
ALTERNATOR...4561
REMOVAL AND INSTALLATION...4561
ENGINE OIL COOLER (SERIAL NO.:50001-52000)...4563
REMOVAL AND INSTALLATION...4563
FUEL INJECTION PUMP (SERIAL NO.:50001-52000)...4564
REMOVAL AND INSTALLATION...4564
WATER PUMP (SERIAL NO.:50001-52000)...4565
REMOVAL AND INSTALLATION...4565
NOZZLE HOLDER (SERIAL NO.:50001-52000)...4566
REMOVAL AND INSTALLATION...4566
TURBOCHARGER (SERIAL NO.:50001-52000)...4567
REMOVALL...4567
INSTALLATION...4568
ENGINE FRONT SEAL (SERIAL NO.:50001-52000)...4569
REPLACEMENT...4569
ENGINE REAR SEAL (SERIAL NO.:50001-52000)...4571
REPLACEMENT...4571
CYLINDER HEAD (SERIAL NO.:50001-52000)...4573
REMOVAL...4573
INSTALLATION...4578
THERMOSTAT (SERIAL NO.:50001-52000)...4580
REMOVAL AND INSTALLATION...4580
AFTERCOOLER CORE (SERIAL NO.:50001-52000)...4581
REMOVAL...4581
INSTALLATION...4582
RADIATOR...4583
REMOVAL...4583
INSTALLATION...4585
RADIATOR (WITH SUCTION FAN)...4590
REMOVAL...4590
INSTALLATION...4593
ENGINE AND TORQUE CONVERTER ASSEMBLY...4594
REMOVAL...4594
INSTALLATION...4596
TORQUE CONVERTER...4601
REMOVAL AND INSTALLATION...4601
DISASSEMBLY...4604
ASSEMBLY...4609
TRANSMISSION...4628
REMOVAL...4628
INSTALLATION...4630
DISASSEMBLY...4631
ASSEMBLY...4646
TRANSMISSION VALVE...4662
REMOVAL AND ASSEMBLY...4662
TRANSFER...4663
DISASSEMBLY...4663
ASSEMBLY...4672
CENTER SUPPORT...4683
REMOVAL AND INSTALLATION...4683
DISASSEMBLY...4685
ASSEMBLY...4687
DRIVE SHAFT...4690
DISASSEMBLY...4690
ASSEMBLY...4693
FRONT AXLE...4696
REMOVAL...4696
INSTALLATION...4697
FRONT DIFFERENTIAL...4698
REMOVAL...4698
INSTALLATION...4699
REAR AXLE...4700
REMOVAL...4700
INSTALLATION...4703
REAR DIFFERENTIAL...4704
REMOVAL...4704
INSTALLATION...4705
DIFFERENTIAL GEAR ...4706
DISASSEMBLY...4706
ASSEMBLY...4710
LIMITED SLIP DIFFERENTIAL...4718
DISASSEMBLY...4718
ASSEMBLY...4723
FINAL DRIVE...4744
REMOAL...4744
ASSEMBLY...4746
ORBIT-ROLL...4749
REMOVAL AND INSTALLATION...4749
STEERING CYLINFER...4750
REMOVAL...4750
INSTALLATION...4751
DISASSEMBLY...4752
ASSEMBLY...4754
STEERING VALVE...4756
REMOVAL...4756
INSTALLATION...4757
CUT-OFF VALVE...4758
REMOVAL AND INSTALLATION...4758
BRAKE VALVE...4759
REMOVAL AND INSTALLATION...4759
BRAKE VALVE (R.H.)...4760
DISASSEMBLY...4760
ASSEMBLY...4762
BRAKE VALVE (L.H.)...4764
DISASSEMBLY...4764
ASSEMBLY...4766
SLACK ADJUSTER...4768
REMOVAL AND INSTALLATION...4768
DISASSEMBLY...4769
ASSEMBLY...4770
BRAKE...4771
REMOVAL AND INSTALLATION...4771
DISASSEMBLY...4772
ASSEMBLY...4775
HYDRAULIC PUMP...4779
REMOVAL...4779
INSTALLATION...4780
HYDRAULIC TANK...4783
REMOVAL...4783
INSTALLATION...4784
HUDRAULIC FILTER...4785
REMOVAL AND INSTALLATION...4785
PPC VALVE...4786
REMOVAL AND INSTALLATION...4786
DISADDEMBLY AND ASSEMBLY...4787
WORK EQUIPMENT VALVE...4788
REMOVAL...4788
INSTALLATION...4789
MAIN CONTROL VALVE...4790
DISASSEMBLY...4790
ASSEMBLY...4793
DUMP CYLINDER...4796
REMOVAL...4796
INSTALLATION...4797
LIFT CYLINDER...4798
REMOVAL...4798
INSTALLATION...4799
LIFT DYLINDER AND DUMP CYLINDER...4800
DISASSEMBLY...4800
ASSEMBLY...4802
CENTER HINGE PIN...4805
REMOVAL...4805
INSTALLATION...4810
WORK EQUIPMENT...4813
REMOVAL...4813
INSTALLATION...4817
BULKHEAD...4819
REMOVAL...4819
INSTALLATION...4820
FLOOR FRAME...4821
REMOVAL...4821
INSTALLATION...4823
COUNTERWEIGHT...4824
REMOVAL AND INSTALLATION...4824
FUEL TANK...4825
REMOVAL...4825
INSTALLATION...4826
CAB...4829
REMOVAL...4829
INSTALLATION...4831
STOP VALVE...4832
REMOVAL AND INSTALLATION...4832
ACCUMULATOR...4833
REMOVAL AND INSTALLATION...4833
ASSUMULATOR CHARGR VALVE...4834
REMOVAL AND INTALLATION...4834
PARKING BRAKE SOLENOID VALVE...4835
REMOVAL AND SINTALLATION...4835
DIVERTER VALVE...4836
REMOVAL AND INSTALLATION...4836
EMERGENCY STEERING PUMP...4837
REMOVAL AND INSTALLATION...4837
PARKING BRAKE...4838
REMOVAL AND INSTALLATION...4838
PARKING BRAKE CALIPERS...4839
DISASSEMBLY...4839
ASSEMBLY...4840
PARKING BRAKE PAD...4841
REMOVAL AND INSTALLATION...4841
REAR TIRES...4842
REMOVAL AND INSTALLATION...4842
AIR CONDITIONER COMPRESSOR...4843
REMOVAL...4843
INSTALLATION...4844
AIR CONDITIONER CONDENSER...4845
REMOVAL AND INSTALLATION...4845
RECEIVER TANK...4846
REMOVAL AND INSTALLATION...4846
AIR CONDITIONER UNIT...4847
REMOVAL...4847
INSTALLATION...4848
MONITOR...4849
REMOVAL AND INSTALLATION...4849
40 MAINTENANCE STANDARD...4850
ENGINE MOUNT...4851
TRANSMISSION MOUNT...4853
TORQUE CONVERTER ...4855
TORQUE CONVERTER REGULATOR VALVE (SERIAL NO.:52001 AND UP)...4858
TRANSMISSION...4859
TRANSFER...4862
TRANSMISSION CONTROL VALVE...4864
DRIVE SHAFT...4869
CENTER SUPPORT...4870
DIFFERENTIAL...4871
LIMITED SLIP DIFFERENTIAL (IF EQUIPPED)...4875
FINAL DRIVE...4879
AXLE MOUNT...4883
STEERING COLUMN...4887
STEERING VLAVE...4888
EMERGENCY STEERING PUMP...4889
DIVERTER VALVE...4890
STEERING CYLINDER MOUNT...4891
BRAKE VALVE...4892
SLACK ADJUSTER...4898
BRAKE...4900
PARKING BRAKE...4904
HYDRAULIC PUMP...4905
PPC VALVE...4910
CUT-OFF VALVE...4912
MAIN CONTROL VALVE...4913
HYDRAULIC CYLINDER...4915
WORK EQUIPMENT LINKAGE...4917
BUCKET...4919
BUCKET POSITIONER AND BOOM KICK-OUT...4920
ROPS CANOPY...4922
90 OTHERS...4923
FOR STANDARD MACHINE (SERIAL NO.:50001-52000)...4924
ELECTRIC CIRCUIT DIAGRAM (1/4)...4924
ELECTRIC CIRCUIT DIAGRAM (2/4)...4925
ELECTRIC CIRCUIT DIAGRAM (3/4)...4926
ELECTRIC CIRCUIT DIAGRAM (4/4)...4927
FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL (SERIAL NO.50001-52000)...4928
ELECTRIC CIRCUIT DIAGRAM (1/4)...4928
ELECTRIC CIRCUIT DIAGRAM (2/4)...4929
ELECTRIC CIRCUIT DIAGRAM (3/4)...4930
ELECTRIC CIRCUIT DIAGRAM (4/4)...4931
FOR STANKARD MACHINE (SERIAL NO.52001 AND UP)...4932
ELECTRIC CIRCUIT DIAGAM (1/5)...4932
ELECTRIC CIRCUIT DIAGAM (2/5)...4933
ELECTRIC CIRCUIT DIAGAM (3/5)...4934
ELECTRIC CIRCUIT DIAGAM (4/5)...4935
ELECTRIC CIRCUIT DIAGAM (5/5)...4936
FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL (SERIAL NO.52001 AND UP)...4937
ELECTRIC CIRCUIT DIAGRAM (1/3)...4937
ELECTRIC CIRCUIT DIAGRAM (2/3)...4938
ELECTRIC CIRCUIT DIAGRAM (3/3)...4939
SEBM013219 - Wheel Loader WA600-3 avance Shop Manual...4940
COVER...4940
CONTENTS...4941
01 GENERAL...4968
GENERAL ASSEMBLY DRAWING...4969
SPECIFICATIONS...4974
WEIGHT TABLE...4980
LIST OF LUBRICANT AND COOLANT...4983
10 STRUCTURE AND FUNCTION...4985
POWER TRAIN...4986
POWER TRAIN SYSTEM...4987
RADIATOR,HYDRAULIC OIL COOLER...4991
RADIATOR, HYDRAULIC OIL COOLER (WITH SUCTION FAN)...4994
TORQUE CONVERTER AND TRANSMISSION PIPING...4996
HYDRAULIC CIRCUIT FOR POWER TRAIN...4998
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN...5000
TORQUE CONVERTER...5004
TORQUE CONVERTER REGULATOR VALVE (SERIAL NO.:52001 AND UP)...5010
TRANSMISSION...5012
TRANSMISSION CONTROL VALVE...5021
TORQUE CONVERTER OIL COOLER...5041
TORQUE CONVERTER OIL FILTER...5042
TRANSFER...5044
DRIVE SHAFT...5045
CENTER SUPPORT...5046
AXLE...5047
DIFFERENTIAL...5049
LIMITED SLIP DIFFERENTIAL(OP)...5052
FINAL DRIVE...5056
AXLE MOUNT...5059
CENTER HINGE PIN...5061
STEERING PIPING...5062
STEERING COLUMN...5065
STEERING UNIT (ORBIT-ROLL VAVLE)...5066
STEERING VALVE...5069
TWO-WAY RESTRICTION VALVE...5080
STOP VALVE...5081
EMERGENCY STEERING PIPING...5082
DIVERTER VALVE (FOR EMERGENCY STEERING)...5083
BRAKE PIPING...5086
BRAKE CIRCUIT DIAGRAM...5090
BRAKE VALVE...5094
CHARGE VALVE...5101
ACCUMULATOR (FOR BRAKE)...5105
SLACK ADJUSTER...5106
BRAKE...5110
PARKING BRAKE...5113
SPRING CYLINDER...5115
PARKING BRAKE SOLENOID VALVE...5116
HYDRAULIC PIPING...5117
...
COMPONENT PARTS OF CONTROL SYSTEM...8448
MACHINE MONITOR...8448
SWITCH PANEL...8468
REARVIEW MONITOR...8469
REARVIEW CAMERA...8471
KOMTRAX TERMINAL...8472
KOMTRAX Plus CONTROLLER...8474
WIRELESS LAN UNIT...8479
TRANSMISSION CONTROLLER...8480
WORK EQUIPMENT CONTROLLER...8485
MONITOR CONTROLLER...8490
CAN TERMINATING RESISTOR...8495
ENGINE CONTROLLER...8496
ACCELERATOR PEDAL...8510
HYDRAULIC SYSTEM...8512
LAYOUT DRAWING OF HYDRAULIC SYSTEM...8512
CLSS...8513
STRUCTURE OF CLSS...8513
FUNCTION OF CLSS...8514
WORK EQUIPMENT PUMP CONTROL SYSTEM...8516
SWASH PLATE CONTROL FUNCTION OF WORK EQUIPMENT PUMP...8516
PICKUP ASSISTANCE CONTROL FUNCTION WHEN ENGINE SPEED IS LOW...8516
COMPONENT PARTS OF HYDRAULIC SYSTEM...8518
HYDRAULIC TANK...8518
WORK EQUIPMENT PUMP...8521
STEERING PUMP...8540
POWER TRAIN CHARGE DUPLEX PUMP...8553
CONTROL VALVE...8554
POWER TRAIN SYSTEM...8589
LAYOUT DRAWING OF POWER TRAIN SYSTEM...8589
OPERATION OF POWER TRAIN SYSTEM...8593
TRANSMISSION CONTROL SYSTEM...8594
TRANSMISSION CONTROL SYSTEM DIAGRAM...8594
TRANSMISSION GEAR SHIFT CONTROL SYSTEM...8598
ELECTRIC MODULATION FUNCTION SYSTEM DIAGRAM...8598
ELECTRIC MODULATION FUNCTION...8599
DISPLAY FUNCTION OF GEAR SHIFT...8599
AUTOMATIC GEAR SHIFT FUNCTION...8599
SHIFT HOLD FUNCTION...8600
KICKDOWN FUNCTION...8601
AUTOMATIC KICKDOWN FUNCTION...8601
TORQUE CONVERTER LOCKUP FUNCTION...8602
HUNTING PREVENTION FUNCTION...8602
ADJUSTING FUNCTION OF TRANSMISSION INITIAL LEARNING AND ECMV CURRENT...8602
SHIFT POINT CHANGING FUNCTION...8603
4TH GEAR SPEED LIMITATION FUNCTION...8603
TRANSMISSION PROTECTION FUNCTION...8604
PROTECTION FUNCTION WHEN TRAVEL DIRECTION IS CHANGED...8604
SHIFT DOWN PROTECTION FUNCTION...8604
ENGINE OVERRUN PREVENTION FUNCTION...8605
NEUTRALIZER FUNCTION...8605
MODULATION CLUTCH CONTROL FUNCTION...8606
MAXIMUM SPEED LIMITATION FUNCTION DURING LOCKUP...8608
COMPONENT PARTS OF POWER TRAIN SYSTEM...8609
DRIVE SHAFT...8609
TORQUE CONVERTER...8612
LOCKUP CLUTCH ECMV...8622
MODULATION CLUTCH ECMV...8625
TRANSMISSION...8628
TRANSMISSION CONTROL VALVE...8645
FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND, 3RD, 4TH CLUTCH ECMV...8648
TRANSFER...8653
TORQUE CONVERTER REGULATOR VALVE...8654
MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE...8656
TRANSMISSION LUBRICATION RELIEF VALVE...8661
AXLE...8662
DIFFERENTIAL...8667
FINAL DRIVE...8672
AJSS KNOB...8674
COMBINATION SWITCH...8675
SHIFT HOLD SWITCH...8679
KICKDOWN SWITCH...8680
WORK EQUIPMENT SYSTEM...8681
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM...8681
WORK EQUIPMENT SYSTEM DIAGRAM...8683
WORK EQUIPMENT CONTROL SYSTEM...8685
WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE...8685
WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION...8686
WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM...8687
WORK EQUIPMENT LEVER OPERATION FUNCTION...8687
BUCKET PRIORITY CONTROL FUNCTION...8688
BOOM STOP MODULATION FUNCTION...8688
WORK EQUIPMENT SHOCK REDUCTION FUNCTION...8689
SUB TOTAL SWITCH INTERLOCK HORN FUNCTION...8692
WORK EQUIPMENT NEUTRAL LOCK SYSTEM...8693
WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM...8693
FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM...8693
REMOTE POSITIONER SYSTEM...8695
REMOTE BUCKET POSITIONER SYSTEM DIAGRAM...8695
FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM...8695
REMOTE BOOM POSITIONER SYSTEM DIAGRAM...8696
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM...8696
BUCKET POSITIONER AND BOOM POSITIONER...8700
STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER...8700
AUTO-DIGGING SYSTEM...8701
AUTO-DIGGING SYSTEM DIAGRAM...8701
FUNCTION OF AUTO-DIGGING SYSTEM...8701
ECSS...8703
ECSS DIAGRAM...8703
FUNCTION OF ECSS...8703
OPERATION OF ECSS...8703
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM...8705
WORK EQUIPMENT LOCK SOLENOID VALVE...8705
PILOT CIRCUIT ACCUMULATOR...8706
ECSS CIRCUIT ACCUMULATOR...8707
WORK EQUIPMENT ELECTRIC LEVER...8708
STEERING SYSTEM...8711
LAYOUT DRAWING OF STEERING SYSTEM...8711
AJSS...8713
LAYOUT DRAWING OF AJSS...8713
AJSS DIAGRAM...8714
FUNCTION OF AJSS...8715
NEUTRALIZER FUNCTION OF AJSS...8717
NEUTRAL INTERLOCK FUNCTION OF AJSS...8717
SPEED SENSING STEERING FUNCTION OF AJSS...8718
TURN SIGNAL PILOT LAMP CONTROL FUNCTION OF AJSS...8720
STEERING COLUMN...8721
STRUCTURE OF STEERING COLUMN...8721
COMPONENT PARTS OF STEERING SYSTEM...8722
AJSS EPC VALVE...8722
STEERING LOCK VALVE...8723
ROTARY VALVE...8724
STEERING UNIT...8727
STOP VALVE...8731
STEERING VALVE...8732
2-WAY RESTRICTOR VALVE...8744
DIVERTER VALVE...8746
SECONDARY STEERING RELIEF VALVE...8752
SECONDARY STEERING PUMP...8754
BRAKE SYSTEM...8755
LAYOUT DRAWING OF BRAKE SYSTEM...8755
PARKING BRAKE CONTROL SYSTEM...8758
PARKING BRAKE CONTROL SYSTEM DIAGRAM...8758
OPERATION OF PARKING BRAKE CONTROL SYSTEM...8758
COMPONENT PARTS OF BRAKE SYSTEM...8760
CHARGE VALVE...8760
PARKING BRAKE SOLENOID VALVE...8766
PARKING BRAKE EMERGENCY RELEASE VALVE...8768
BRAKE CIRCUIT ACCUMULATOR...8769
BRAKE VALVE...8770
SLACK ADJUSTER...8776
BRAKE...8778
PARKING BRAKE...8780
BRAKE COOLING PUMP...8782
UNDERCARRIAGE AND FRAME...8783
FRAME, AXLE MOUNT AND CENTER HINGE PIN...8783
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN...8783
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN...8785
TIRE...8786
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE...8786
STRUCTURE OF RADIAL TIRE...8786
FUNCTION OF RADIAL TIRE...8786
STRUCTURE OF BIAS TIRE...8787
FUNCTION OF BIAS TIRE...8787
WORK EQUIPMENT...8788
STRUCTURE OF WORK EQUIPMENT...8788
STRUCTURE OF BUCKET...8789
STRUCTURE OF WORK EQUIPMENT LUBRICATION...8790
CAB AND ITS ATTACHMENTS...8792
ROPS CAB...8792
STRUCTURE OF ROPS CAB...8792
FUNCTION OF ROPS CAB...8793
20 STANDARD VALUE TABLE...8795
CONTENTS...8796
ABBREVIATION LIST...8797
STANDARD VALUE TABLE FOR ENGINE...8802
STANDARD VALUE TABLE FOR ENGINE: WA600-8...8802
STANDARD VALUE TABLE FOR MACHINE...8805
STANDARD VALUE TABLE FOR MACHINE: WA600-8...8805
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE...8824
30 TESTING AND ADJUSTING...8827
CONTENTS...8828
ABBREVIATION LIST...8832
RELATED INFORMATION ON TESTING AND ADJUSTING...8837
TOOLS FOR TESTING AND ADJUSTING...8837
SKETCH OF TOOLS FOR TESTING AND ADJUSTING...8849
ENGINE AND COOLING SYSTEM...8850
TEST ENGINE SPEED...8850
METHOD FOR TESTING ENGINE SPEED...8850
TEST BOOST PRESSURE...8854
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR...8854
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL...8855
TESTING EXHAUST GAS TEMPERATURE...8858
METHOD FOR TESTING EXHAUST GAS TEMPERATURE...8858
TEST EXHAUST GAS COLOR...8860
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER...8860
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER...8861
TEST AND ADJUST VALVE CLEARANCE...8863
METHOD FOR TESTING VALVE CLEARANCE...8863
METHOD FOR ADJUSTING VALVE CLEARANCE...8864
TEST COMPRESSION PRESSURE...8866
METHOD FOR TESTING COMPRESSION PRESSURE...8866
TEST BLOWBY PRESSURE...8870
METHOD FOR TESTING BLOWBY PRESSURE...8870
TEST ENGINE OIL PRESSURE...8873
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR...8873
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL...8874
TEST EGR VALVE AND KVGT OIL PRESSURE...8876
METHOD FOR TESTING EGR VALVE AND KVGT OIL PRESSURE...8876
TEST FUEL PRESSURE...8878
METHOD FOR TESTING FUEL PRESSURE...8878
TEST FUEL RETURN RATE AND LEAKAGE...8880
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE...8881
BLEEDING AIR FROM FUEL SYSTEM...8884
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM...8884
TEST FUEL CIRCUIT FOR LEAKAGE...8886
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE...8886
TEST SUPPLY PUMP...8888
METHOD FOR TESTING SUPPLY PUMP...8888
HANDLE CYLINDER CUT-OUT MODE OPERATION...8891
HANDLE NO-INJECTION CRANKING OPERATION...8892
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE...8893
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE...8893
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS...8894
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS...8894
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS...8895
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS...8895
CLEAN FUEL DOSER...8896
METHOD FOR CLEANING FUEL DOSER...8896
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER...8898
METHOD FOR WRITING INJECTOR COMPENSATION VALUE...8898
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER...8905
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER...8905
TEST SCR RELATED FUNCTIONS...8906
TEST AdBlue/DEF PUMP RAISED PRESSURE...8910
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR...8916
TEST AdBlue/DEF LINE HEATER RELAY 1...8925
TEST AdBlue/DEF LINE HEATER RELAY 2...8933
TEST AdBlue/DEF PUMP HEATER RELAY...8940
TEST AdBlue/DEF TANK HEATER VALVE...8947
TEST SCR NOx REMOVAL EFFICIENCY...8951
CLEAN AdBlue/DEF TANK...8956
METHOD FOR CLEANING AdBlue/DEF TANK...8956
POWER TRAIN...8961
TEST AND ADJUST POWER TRAIN OIL PRESSURE...8961
METHOD FOR TESTING POWER TRAIN OIL PRESSURE...8963
METHOD FOR ADJUSTING POWER TRAIN OIL PRESSURE...8976
ADJUST MODULATION CLUTCH ROTATION SENSOR...8978
METHOD FOR ADJUSTING MODULATION CLUTCH ROTATION SENSOR...8978
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR...8979
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR...8979
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT...8981
METHOD FOR FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT...8981
MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE...8984
METHOD FOR MOVING DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE...8985
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE...8987
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE...8987
STEERING SYSTEM...8988
TEST STEERING WHEEL (FOR STEERING WHEEL SPEC)...8988
METHOD FOR TESTING STEERING WHEEL...8988
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE...8990
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE...8990
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE...8994
BLEED AIR FROM STEERING CYLINDER CIRCUIT...8995
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT...8995
TEST AND ADJUST STEERING STOP VALVE (FOR STEERING WHEEL SPEC)...8996
METHOD FOR TESTING STEERING STOP VALVE...8996
METHOD FOR ADJUSTING STEERING STOP VALVE...8996
BRAKE SYSTEM...8998
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT...8998
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT...8998
TEST WHEEL BRAKE OIL PRESSURE...8999
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE...8999
TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE...9001
METHOD FOR TESTING BRAKE ACCUMULATOR CHARGE PRESSURE BY MACHINE MONITOR...9001
METHOD FOR TESTING BRAKE ACCUMULATOR CHARGE PRESSURE BY TESTING TOOL...9002
METHOD FOR ADJUSTING BRAKE ACCUMULATOR CHARGE PRESSURE...9003
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE...9005
METHOD FOR TESTING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE...9005
METHOD FOR CHARGING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE...9008
TEST BRAKING PERFORMANCE...9011
METHOD FOR TESTING BRAKING PERFORMANCE...9011
TEST BRAKE PEDAL...9012
METHOD FOR TESTING BRAKE PEDAL...9012
ADJUST RH BRAKE PEDAL SWITCH...9013
METHOD FOR ADJUSTING RH BRAKE PEDAL SWITCH...9013
BLEED AIR FROM BRAKE CIRCUIT...9015
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT...9015
TEST WEAR OF WHEEL BRAKE DISC...9016
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC...9016
TEST PARKING BRAKE OIL PRESSURE...9018
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE...9018
TEST PARKING BRAKE PERFORMANCE...9022
METHOD FOR TESTING PARKING BRAKE PERFORMANCE...9022
RELEASE PARKING BRAKE MANUALLY...9023
METHOD FOR RELEASING PARKING BRAKE MANUALLY...9023
TEST WEAR AMOUNT OF PARKING BRAKE DISC...9025
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC...9025
HYDRAULIC SYSTEM...9026
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT...9026
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT...9026
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE...9028
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE...9028
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE...9033
TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE...9035
METHOD FOR TESTING WORK EQUIPMENT EPC OIL PRESSURE...9035
METHOD FOR ADJUSTING WORK EQUIPMENT EPC OIL PRESSURE...9037
BLEED AIR FROM WORK EQUIPMENT CIRCUIT...9038
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT...9038
TEST COOLING FAN SPEED...9039
METHOD FOR TESTING COOLING FAN SPEED...9039
TEST COOLING FAN CIRCUIT OIL PRESSURE...9041
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE...9041
BLEED AIR FROM COOLING FAN CIRCUIT...9043
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT...9043
TEST ECSS ACCUMULATOR CHARGE PRESSURE...9045
METHOD FOR TESTING ECSS ACCUMULATOR CHARGE PRESSURE...9045
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS...9047
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE...9047
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS...9049
WORK EQUIPMENT...9053
TEST AND ADJUST BUCKET POTENTIOMETER LEVER...9053
METHOD FOR TESTING BUCKET POTENTIOMETER LEVER...9053
METHOD FOR ADJUSTING BUCKET POTENTIOMETER LEVER...9053
TEST AND ADJUST BOOM POTENTIOMETER LEVER...9055
METHOD FOR TESTING BOOM POTENTIOMETER LEVER...9055
METHOD FOR ADJUSTING BOOM POTENTIOMETER LEVER...9055
CAB AND ITS ATTACHMENTS...9056
TEST DIRECTIONAL LEVER (FOR STEERING WHEEL SPEC)...9056
METHOD FOR TESTING DIRECTIONAL LEVER...9056
TEST WORK EQUIPMENT CONTROL LEVER...9057
METHOD FOR TESTING WORK EQUIPMENT CONTROL LEVER...9057
TEST AJSS LEVER (FOR AJSS SPEC)...9059
METHOD FOR TESTING AJSS LEVER...9059
TEST AND ADJUST AJSS LEVER/FRAME ANGLE SENSOR (FOR AJSS SPEC)...9062
METHOD FOR TESTING AJSS LEVER/FRAME ANGLE SENSOR...9062
METHOD FOR ADJUSTING AJSS LEVER/FRAME ANGLE SENSOR...9062
TEST AND AJUST STEERING STOPPER BOLT (FOR AJSS SPEC)...9064
METHOD FOR TESTING STEERING STOPPER VALVE...9064
METHOD FOR ADJUSTING STEERING STOPPER VALVE...9064
ADJUST RATTLING OPERATOR'S SEAT...9066
METHOD FOR ADJUSTING RATTLING OPERATOR'S SEAT...9066
ADJUST DOOR LOCK LINK...9067
METHOD FOR ADJUSTING DOOR LOCK LINK...9067
ELECTRICAL SYSTEM...9070
SET AND ADJUST EACH EQUIPMENT...9070
SET AND OPERATE MACHINE MONITOR...9075
OPERATOR MODE...9079
SERVICE MODE...9085
METHOD FOR STARTING UP KOMTRAX TERMINAL...9209
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER...9214
METHOD FOR SETTING WITH DEFAULT SETTING OF KOMTRAX Plus CONTROLLER...9214
SETTING DEFAULT OF WIRELESS LAN MODEM...9217
METHOD FOR SETTING DEFAULT OF WIRELESS LAN MODEM...9217
METHOD FOR CHECKING OF WIRELESS LAN MODEM COMMUNICATION...9218
DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA...9220
METHOD FOR DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA...9220
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED...9224
METHOD FOR ADJUSTING WHEN KOMTRAX Plus CONTROLLER IS REPLACED...9224
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED...9227
METHOD FOR ADJUSTING WHEN WIRELESS LAN MODEM IS REPLACED...9227
ADJUST REARVIEW CAMERA ANGLE...9230
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE...9230
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER...9231
HANDLE BATTERY DISCONNECT SWITCH...9232
TEST DIODES...9233
METHOD FOR TESTING DIODE USING DIGITAL TESTER...9233
METHOD FOR TESTING DIODE USING ANALOG TESTER...9233
Pm CLINIC...9234
Pm CLINIC SERVICE...9234
Pm CLINIC CHECK SHEET: WA600-8...9237
PERFORMING QUICK Pm...9248
METHOD FOR PERFORMING QUICK Pm...9248
40 TROUBLESHOOTING...9251
CONTENTS...9252
ABBREVIATION LIST...9268
RELATED INFORMATION ON TROUBLESHOOTING...9273
GENERAL TROUBLESHOOTING POINTS...9273
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM...9274
SEQUENCE OF EVENTS IN TROUBLESHOOTING...9289
CHECKS BEFORE TROUBLESHOOTING...9291
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING...9293
WALK-AROUND CHECK...9293
TESTING IN ACCORDANCE WITH TESTING PROCEDURE...9295
FUEL - CHECK LEVEL AND TYPE...9295
FUEL - CHECK FOR FOREIGN MATERIAL...9295
CHECK AdBule/DEF LEVEL AND TYPE...9296
FUEL PREFILTER - CHECK...9296
MAIN FILTER - CHECK...9298
OIL PAN - CHECK ENGINE OIL LEVEL AND TYPE...9300
RESERVOIR TANK - CHECK COOLANT LEVEL...9300
AIR CLEANER - CHECK FOR CLOGGING...9301
OUTER ELEMENT - CLEAN...9303
REPLACE ELEMENT...9305
CHECK HYDRAULIC OIL LEVEL...9306
CHECK HYDRAULIC OIL STRAINER...9307
CHECK HYDRAULIC FILTER...9308
CHECK OIL LEVEL IN TRANSMISSION CASE...9309
CHECK OIL LEVEL IN AXLE CASE...9311
BLEED AIR FROM FUEL SYSTEM...9312
BLEED AIR FROM HYDRAULIC SYSTEM...9312
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod...9312
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION...9319
PROCEDURE FOR TESTING AND TROUBLESHOOTING...9329
SYMPTOM AND TROUBLESHOOTING NUMBERS...9331
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...9335
CONNECTORS LIST AND LAYOUT...9337
CONNECTOR CONTACT IDENTIFICATION...9363
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE...9403
FUSE LOCATION TABLE...9409
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)...9412
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR...9416
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT...9418
PREPARATION OF SHORT SOCKET ADAPTER (FOR FAILURE CODES [CA1883], [CB1883], [CA3135] AND [CB3135])...9424
FAILURE CODES TABLE...9426
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)...9457
FAILURE CODE [1500L0] T/M Clutches Double Engagement...9457
FAILURE CODE [15SAL1] ECMV Release Trouble (Forward)...9458
FAILURE CODE [15SALH] ECMV Engage Trouble (Forward)...9460
FAILURE CODE [15SBL1] ECMV Release Trouble (Reverse Clutch)...9462
FAILURE CODE [15SBLH] ECMV Engage Trouble (Reverse)...9464
FAILURE CODE [15SEL1] ECMV Release Trouble (1st Clutch)...9466
FAILURE CODE [15SELH] ECMV Engage Trouble (1st)...9468
FAILURE CODE [15SFL1] ECMV Release Trouble (2nd Clutch)...9470
FAILURE CODE [15SFLH] ECMV Engage Trouble (2nd)...9472
FAILURE CODE [15SGL1] ECMV Release Trouble (3rd Clutch)...9474
FAILURE CODE [15SGLH] ECMV Engage Trouble (3rd)...9476
FAILURE CODE [15SHL1] ECMV Release Trouble (4th)...9478
FAILURE CODE [15SHLH] ECMV Engage Trouble (4th)...9480
FAILURE CODE [15W0NT] Mod/C Overheat...9482
FAILURE CODE [2F00MA] Parking Brake Defective Function...9483
FAILURE CODE [2F00MB] Malfunction of Parking Brake...9487
FAILURE CODE [2G42ZG] Accumulator Oil Pressure Low (Front)...9490
FAILURE CODE [2G43ZG] Accumulator Oil Pressure Low (Rear)...9492
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit...9494
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit...9495
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit...9496
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit...9498
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit...9500
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit...9501
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit...9502
FAILURE CODE [879EMC] Ventilation Damper Malfunction...9504
FAILURE CODE [879FMC] Air Mix Damper Malfunction...9505
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range...9506
FAILURE CODE [989A00] Engine Overrun...9508
FAILURE CODE [989L00] Engine Controller Lock Caution 1...9509
FAILURE CODE [989M00] Engine Controller Lock Caution 2...9510
FAILURE CODE [989N00] Engine Controller Lock Caution 3...9511
FAILURE CODE [A1U0N3] HC Desorb Request 1...9512
FAILURE CODE [A1U0N4] HC Desorb Request 2...9514
FAILURE CODE [AA10NX] Air Cleaner Clogging...9516
FAILURE CODE [AB00KE] Charge Voltage Low...9518
FAILURE CODE [AB00KY] Hot Short of Alternator R Terminal...9520
FAILURE CODE [AQ00N3] KDPF System Imbalance Soot Load 1...9522
FAILURE CODE [AQ00N4] KDPF System Imbalance Soot Load 2...9523
FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging)...9524
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR)...9526
FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality)...9528
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality)...9529
FAILURE CODE [AS00R4] Inducement 2 (SCR Device Abnormality)...9530
FAILURE CODE [AS00R5] Inducement 3 (SCR Device Abnormality)...9531
FAILURE CODE [AS00R6] Temporary Recovery of Inducement...9532
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5...9533
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning...9534
FAILURE CODE [B@BAZG] Eng Oil Press Low...9535
FAILURE CODE [B@BAZK] Eng Oil Level Low...9536
FAILURE CODE [B@BCNS] Engine Coolant Overheat...9538
FAILURE CODE [B@BCZK] Engine Coolant Level Low...9539
FAILURE CODE [B@C7NS] Brake Oil Temp. Overheat (Rear)...9541
FAILURE CODE [B@CENS] Power Train Oil Overheat...9543
FAILURE CODE [B@GAZK] Battery Elctrolyte Level Low...9544
FAILURE CODE [B@HANS] Hydraulic Oil Overheat...9545
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error...9546
FAILURE CODE [CA122] Charge Air Pressure Sensor High Error...9550
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error...9552
FAILURE CODE [CA131] Throttle Sensor High Error...9554
FAILURE CODE [CA132] Throttle Sensor Low Error...9556
FAILURE CODE [CA135] Engine Oil Pressure Sensor High Error...9558
FAILURE CODE [CA141] Engine Oil Pressure Sensor Low Error...9560
FAILURE CODE [CA144] Coolant Temperature Sensor High Error...9562
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error...9564
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error...9566
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error...9569
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error...9571
FAILURE CODE [CA212] Engine Oil Temperature Sensor High Error...9573
FAILURE CODE [CA213] Engine Oil Temperature Sensor Low Error...9575
FAILURE CODE [CA221] Ambient Pressure Sensor High Error...9577
FAILURE CODE [CA222] Ambient Pressure Sensor Low Error...9579
FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error...9581
FAILURE CODE [CA234] Engine Overspeed...9583
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error...9584
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error...9586
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error...9588
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error...9590
FAILURE CODE [CA271] IMV or PCV 1 Short Circuit Error...9592
FAILURE CODE [CA272] IMV or PCV 1 Open Circuit Error...9594
FAILURE CODE [CA273] PCV 2 Short Circuit Error...9595
FAILURE CODE [CA274] PCV 2 Open Circuit Error...9597
FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Circuit Error...9598
FAILURE CODE [CA323] Injector #5 (L#5) Open Circuit Error or Short Circuit Error...9600
FAILURE CODE [CA324] Injector #3 (L#3) Open Circuit Error or Short Circuit Error...9602
FAILURE CODE [CA325] Injector #6 (L#6) Open Circuit Error or Short Circuit Error...9604
FAILURE CODE [CA331] Injector #2 (L#2) Open Circuit Error or Short Circuit Error...9606
FAILURE CODE [CA332] Injector #4 (L#4) Open Circuit Error or Short Circuit Error...9608
FAILURE CODE [CA343] Engine Controller Internal Abnormality...9610
FAILURE CODE [CA351] Injectors Drive Circuit Error...9612
FAILURE CODE [CA352] Sensor 1 Supply Voltage Low Error...9614
FAILURE CODE [CA356] MAF Sensor High Error...9616
FAILURE CODE [CA357] MAF Sensor Low Error...9618
FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error...9620
FAILURE CODE [CA431] Idle Validation Sw Error...9622
FAILURE CODE [CA432] Idle Validation Process Error...9625
FAILURE CODE [CA441] Battery Voltage Low Error...9628
FAILURE CODE [CA442] Battery Voltage High Error...9630
FAILURE CODE [CA449] Common Rail Pressure High Error 2...9632
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error...9633
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error...9635
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error...9637
FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage Low Error...9639
FAILURE CODE [CA553] Common Rail Pressure High Error 1...9641
FAILURE CODE [CA555] Crankcase Pressure High Error 1...9642
FAILURE CODE [CA556] Crankcase Pressure High Error 2...9644
FAILURE CODE [CA559] Common Rail Pressure Low Error 1...9646
FAILURE CODE [CA595] Turbocharger Speed High Error 2...9651
FAILURE CODE [CA687] Turbocharger Speed Low Error...9653
FAILURE CODE [CA689] Engine NE Speed Sensor Error...9655
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error...9657
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error...9659
FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor High Error...9661
FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor Low Error...9662
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error...9663
FAILURE CODE [CA778] Engine Backup Speed Sensor Error...9666
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error...9668
FAILURE CODE [CA1135] CEN Communication Error...9670
FAILURE CODE [CA1257] Multi-controller ID Harness Key Error...9672
FAILURE CODE [CA1664] KDOC Abnormality...9673
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error...9677
FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3...9678
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error...9679
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error...9680
FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error...9681
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error...9683
FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error...9685
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error...9687
FAILURE CODE [CA1691] Defective Regeneration...9688
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error...9690
FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error...9692
FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error...9694
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error...9696
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error...9699
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error...9701
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error...9702
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error...9703
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error...9705
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error...9708
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error...9710
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error...9712
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error...9714
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Error...9716
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error...9720
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error...9722
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1...9724
FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 2...9727
FAILURE CODE [CA1923] Fuel Doser Solenoid 1 High Error...9732
FAILURE CODE [CA1924] Fuel Doser Solenoid 1 Low Error...9734
FAILURE CODE [CA1925] Fuel Doser Solenoid 1 In Range Error...9736
FAILURE CODE [CA1927] Dosing Fuel Pressure Sensor High Error...9738
FAILURE CODE [CA1928] Dosing Fuel Pressure Sensor Low Error...9740
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error...9742
FAILURE CODE [CA1963] Fuel Doser Solenoid 1 Servo Error...9744
FAILURE CODE [CA1977] Fuel Doser Open Error or Short Error...9747
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error...9749
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error...9752
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error...9754
FAILURE CODE [CA2249] Common Rail Pressure Low Error 2...9756
FAILURE CODE [CA2265] Fuel Feed Pump Open Circuit Error...9761
FAILURE CODE [CA2266] Fuel Feed Pump Short Circuit Error...9763
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error...9765
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error...9767
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error...9769
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error...9771
FAILURE CODE [CA2357] EGR Valve Servo Error...9773
FAILURE CODE [CA2381] KVGT Position Sensor High Error...9776
FAILURE CODE [CA2382] KVGT Position Sensor Low Error...9778
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error...9780
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error...9782
FAILURE CODE [CA2387] KVGT Servo Error...9784
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error...9787
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error...9789
FAILURE CODE [CA2637] KDOC Face Plugging...9791
FAILURE CODE [CA2639] Manual Stationary Regeneration Request...9793
FAILURE CODE [CA2732] Fuel Doser Solenoid 2 High Error...9796
FAILURE CODE [CA2733] Fuel Doser Solenoid 2 Low Error...9798
FAILURE CODE [CA2741] Fuel Dozer Solenoid Valve Swap Error...9800
FAILURE CODE [CA2765] Injector Trim Data Mismatch...9801
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error...9802
FAILURE CODE [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable...9808
FAILURE CODE [CA2878] Fuel Doser Solenoid 2 Servo Error...9811
FAILURE CODE [CA2881] Dosing Fuel Pressure Low Error 1...9814
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error...9817
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error...9819
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error...9821
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error...9823
FAILURE CODE [CA3142] SCR Temperature Sensor High Error...9827
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error...9828
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error...9829
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error...9832
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error...9833
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error...9834
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2...9837
FAILURE CODE [CA3165] SCR Outlet Temperature High Error...9842
FAILURE CODE [CA3167] Fuel Doser Degradation...9844
FAILURE CODE [CA3229] SCR Temperature High Error...9848
FAILURE CODE [CA3231] SCR Temperature High Error - Non Regeneration...9851
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error...9854
FAILURE CODE [CA3235] SCR Outlet Temperature High Error - Non Regeneration...9859
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error...9861
FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error...9864
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error...9867
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error...9870
FAILURE CODE [CA3253] KDOC Temperature Error - Non Regeneration...9873
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1...9878
FAILURE CODE [CA3255] KDPF Temperature Error - Non Regeneration...9882
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1...9885
FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2...9888
FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2...9891
FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error...9894
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error...9895
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error...9896
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error...9900
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error...9901
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error...9902
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error...9906
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error...9907
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error...9908
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error...9912
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error...9914
FAILURE CODE [CA3497] AdBlue/DEF Level Low Error 1...9916
FAILURE CODE [CA3498] AdBlue/DEF Level Low Error 2...9917
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low)...9918
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error...9923
FAILURE CODE [CA3547] AdBlue/DEF Level Low Error 4...9925
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error...9926
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error...9928
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error...9930
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error...9932
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error...9935
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction...9939
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error...9943
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error...9945
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error...9947
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error...9950
FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error...9952
FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error...9954
FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 1...9956
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Error...9961
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error...9964
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error...9968
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error...9971
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error...9976
FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error...9982
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error...9985
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error...9986
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error...9987
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error...9990
FAILURE CODE [CA3751] SCR Catalyst Degradation Error...9992
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error...9994
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2...9996
FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 1...9999
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error...10002
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error...10006
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error...10008
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error...10012
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error...10014
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error...10016
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error...10018
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error...10021
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error...10023
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error...10025
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error...10029
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error...10033
FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error...10036
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction...10039
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error...10041
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error...10042
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error...10043
FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error...10046
FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error...10049
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error...10051
FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error...10054
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error...10057
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error...10059
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error...10064
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error...10069
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error...10074
FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error...10079
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error...10084
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error...10088
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error...10091
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error...10094
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error...10098
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error...10101
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error...10104
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error...10108
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data Error...10109
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error...10110
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error...10111
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible...10113
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error...10116
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine Controller)...10119
FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error...10121
FAILURE CODE [CA5179] Engine Room Temperature Sensor High Error...10124
FAILURE CODE [CA5181] Engine Room Temperature Sensor Low Error...10126
FAILURE CODE [CA5383] Ash Accumulation High Error...10128
FAILURE CODE [CB115] Engine NE and Backup Speed Sensor Error_2...10130
FAILURE CODE [CB187] Sensor Supply_2 Voltage Low Error_2...10133
FAILURE CODE [CB227] Sensor Supply_2 Voltage High Error_2...10135
FAILURE CODE [CB238] NE Speed Sensor Supply Voltage Error_2...10136
FAILURE CODE [CB239] NE Speed Sensor Supply Voltage High Error_2...10138
FAILURE CODE [CB271] IMV or PCV 1 Short Circuit Error_2...10140
FAILURE CODE [CB272] IMV or PCV 1 Open Circuit Error_2...10142
FAILURE CODE [CB273] PCV_2 Short Circuit Error_2...10143
FAILURE CODE [CB274] PCV_2 Open Circuit Error_2...10145
FAILURE CODE [CB343] Engine Controller Internal Abnormality_2...10146
FAILURE CODE [CB352] Sensor Supply 1 Voltage Low Error_2...10148
FAILURE CODE [CB386] Sensor Supply 1 Voltage High Error_2...10150
FAILURE CODE [CB441] Power Voltage Low Error_2...10152
FAILURE CODE [CB442] Power Voltage High Error_2...10154
FAILURE CODE [CB689] Engine NE Speed Sensor Error_2...10156
FAILURE CODE [CB697] Engine Controller Internal Temperature Sensor High Error_2...10158
FAILURE CODE [CB698] Engine Controller Internal Temperature Sensor Low Error_2...10159
FAILURE CODE [CB731] Engine Backup Speed Sensor Phase Error_2...10160
FAILURE CODE [CB778] Engine Backup Speed Sensor Error_2...10163
FAILURE CODE [CB1117] Engine Controller Partial Data Lost Error_2...10165
FAILURE CODE [CB1257] Multi-controller ID Harness Key Error_2...10167
FAILURE CODE [CB1664] KDOC Abnormality_2...10168
FAILURE CODE [CB1682] AdBlue/DEF Pump Fail To Prime Error_2...10171
FAILURE CODE [CB1691] Defective Regeneration_2...10173
FAILURE CODE [CB1694] SCR Outlet NOx Sensor In Range Error_2...10175
FAILURE CODE [CB1695] Sensor Supply 5 Voltage High Error_2...10177
FAILURE CODE [CB1696] Sensor Supply 5 Voltage Low Error_2...10179
FAILURE CODE [CB1776] Sensor Supply Relay Volt High Error_2...10181
FAILURE CODE [CB1777] Sensor Supply Relay Volt Low Error_2...10184
FAILURE CODE [CB1879] KDPF Differential Pressure Sensor High Error_2...10187
FAILURE CODE [CB1881] KDPF Differential Pressure Sensor Low Error_2...10189
FAILURE CODE [CB1883] KDPF Differential Pressure Sensor In Range Error_2...10191
FAILURE CODE [CB1887] SCR Outlet NOx Sensor Circuit Error_2...10195
FAILURE CODE [CB1921] KDPF Soot Accumulation High Error 1_2...10197
FAILURE CODE [CB1922] KDPF Soot Accumulation High Error 2_2...10200
FAILURE CODE [CB1923] Fuel Doser Solenoid 1 High Error_2...10205
FAILURE CODE [CB1924] Fuel Doser Solenoid 1 Low Error_2...10207
FAILURE CODE [CB1925] Fuel Doser Solenoid 1 In Range Error_2...10209
FAILURE CODE [CB1927] Dosing Fuel Pressure Sensor High Error_2...10211
FAILURE CODE [CB1928] Dosing Fuel Pressure Sensor Low Error_2...10213
FAILURE CODE [CB1963] Fuel Doser Solenoid 1 Servo Error_2...10215
FAILURE CODE [CB1977] Fuel Doser Open Circuit Error or Short Circuit Error_2...10218
FAILURE CODE [CB1993] KDPF Differential Pressure Low Error_2...10220
FAILURE CODE [CB2265] Fuel Feed Pump Open Circuit Error_2...10223
FAILURE CODE [CB2266] Fuel Feed Pump Short Circuit Error_2...10225
FAILURE CODE [CB2637] KDOC Face Plugging_2...10227
FAILURE CODE [CB2639] Manual Stationary Regeneration Request_2...10229
FAILURE CODE [CB2732] Fuel Doser Solenoid_2 High Error_2...10232
FAILURE CODE [CB2733] Fuel Doser Solenoid_2 Low Error_2...10234
FAILURE CODE [CB2741] Fuel Dozer Solenoid Valve Swap Error_2...10236
FAILURE CODE [CB2771] SCR Outlet NOx Sensor Datalink Timeout Error_2...10237
FAILURE CODE [CB2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable_2...10243
FAILURE CODE [CB2878] Fuel Doser Solenoid_2 Servo Error_2...10246
FAILURE CODE [CB2881] Dosing Fuel Pressure Low Error 1_2...10249
FAILURE CODE [CB2976] AdBlue/DEF Pump Temp Sensor Signal Error_2...10252
FAILURE CODE [CB3133] KDPF Outlet Pressure Sensor High Error_2...10254
FAILURE CODE [CB3134] KDPF Outlet Pressure Sensor Low Error_2...10256
FAILURE CODE [CB3135] KDPF Outlet Pressure Sensor In Range Error_2...10258
FAILURE CODE [CB3142] SCR Temperature Sensor High Error_2...10262
FAILURE CODE [CB3143] SCR Temperature Sensor Low Error_2...10263
FAILURE CODE [CB3144] SCR Temperature Sensor In Range Error_2...10264
FAILURE CODE [CB3146] SCR Outlet Temp Sensor Volt High Error_2...10267
FAILURE CODE [CB3147] SCR Outlet Temp Sensor Volt Low Error_2...10268
FAILURE CODE [CB3148] SCR Outlet Temp Sensor In Range Error_2...10269
FAILURE CODE [CB3151] SCR Catalyst Efficiency Low 2 Error_2...10272
FAILURE CODE [CB3165] SCR Outlet Temp High Error_2...10277
FAILURE CODE [CB3167] Fuel Doser Degradation_2...10279
FAILURE CODE [CB3229] SCR Temp High Error_2...10283
FAILURE CODE [CB3231] SCR Temp High Error - Non Regeneration_2...10286
FAILURE CODE [CB3235] SCR Outlet Temp High Error - Non Regeneration_2...10289
FAILURE CODE [CB3239] AdBlue/DEF Line Heater_2 Volt High Error_2...10291
FAILURE CODE [CB3241] AdBlue/DEF Line Heater_2 Volt Low Error_2...10294
FAILURE CODE [CB3251] KDOC Inlet Temperature High Error_2...10297
FAILURE CODE [CB3253] KDOC Temperature Error - Non Regeneration_2...10300
FAILURE CODE [CB3254] KDOC Outlet Temperature High Error 1_2...10305
FAILURE CODE [CB3255] KDPF Temperature Error - Non Regeneration_2...10309
FAILURE CODE [CB3256] KDPF Outlet Temperature High Error 1_2...10312
FAILURE CODE [CB3311] KDOC Outlet Temperature High Error 2_2...10315
FAILURE CODE [CB3312] KDPF Outlet Temperature High Error 2_2...10318
FAILURE CODE [CB3313] KDOC Inlet Temperature Sensor Low Error_2...10321
FAILURE CODE [CB3314] KDOC Inlet Temperature Sensor High Error_2...10322
FAILURE CODE [CB3315] KDOC Inlet Temperature Sensor In Range Error_2...10323
FAILURE CODE [CB3316] KDOC Outlet Temperature Sensor Low Error_2...10327
FAILURE CODE [CB3317] KDOC Outlet Temperature Sensor High Error_2...10328
FAILURE CODE [CB3318] KDOC Outlet Temperature Sensor In Range Error_2...10329
FAILURE CODE [CB3319] KDPF Outlet Temperature Sensor High Error_2...10333
FAILURE CODE [CB3321] KDPF Outlet Temperature Sensor Low Error_2...10334
FAILURE CODE [CB3322] KDPF Outlet Temperature Sensor In Range Error_2...10335
FAILURE CODE [CB3545] SCR Outlet NOx Sensor Not Valid Error_2...10339
FAILURE CODE [CB3558] AdBlue/DEF Pump Volt High Error_2...10341
FAILURE CODE [CB3559] AdBlue/DEF Pump Volt Low Error_2...10343
FAILURE CODE [CB3562] AdBlue/DEF LineHeater Relay 1 Volt High Error_2...10345
FAILURE CODE [CB3563] AdBlue/DEF LineHeater Relay 1 Volt Low Error_2...10347
FAILURE CODE [CB3567] AdBlue/DEF Injector Open/Short Error_2...10350
FAILURE CODE [CB3568] AdBlue/DEF Injector Function Response Error_2...10354
FAILURE CODE [CB3571] AdBlue/DEF Press Sensor Volt High Error_2...10358
FAILURE CODE [CB3572] AdBlue/DEF Press Sensor Volt Low Error_2...10360
FAILURE CODE [CB3574] AdBlue/DEF Press Too Low Error_2...10362
FAILURE CODE [CB3575] AdBlue/DEF Press Too High Error_2...10365
FAILURE CODE [CB3577] AdBlue/DEF FCV Volt High Error_2...10367
FAILURE CODE [CB3578] AdBlue/DEF FCV Volt Low Error_2...10369
FAILURE CODE [CB3582] SCR Catalyst Efficiency Low 1 Error_2...10371
FAILURE CODE [CB3583] SCR Outlet NOx Sensor Heater Warmup Error_2...10377
FAILURE CODE [CB3596] AdBlue/DEF Press Fail To Stabilize Error_2...10379
FAILURE CODE [CB3681] SCR Outlet NOx Sensor Power Error_2...10383
FAILURE CODE [CB3713] AdBlue/DEF Line Heater 1 Voltage High Error_2...10388
FAILURE CODE [CB3717] SCR Outlet NOx Sensor Voltage Mismatch Error_2...10391
FAILURE CODE [CB3751] SCR Catalyst Degradation Error_2...10392
FAILURE CODE [CB3755] AdBlue/DEF Dosing Performance Degradation Error_2...10394
FAILURE CODE [CB3899] SCR NH3 Sensor Circuit Error_2...10396
FAILURE CODE [CB3911] SCR NH3 Sensor Datalink Timeout Error_2...10398
FAILURE CODE [CB3912] SCR NH3 Sensor Heater Warming up Error_2...10402
FAILURE CODE [CB3932] SCR NH3 Sensor Heater Voltage High Error_2...10404
FAILURE CODE [CB3933] SCR NH3 Sensor Heater Voltage Low Error_2...10406
FAILURE CODE [CB3934] SCR NH3 Sensor Power Interrupt Error_2...10408
FAILURE CODE [CB3935] SCR NH3 Sensor Trim Resistance Error_2...10410
FAILURE CODE [CB3936] SCR NH3 Sensor Internal Circuit Error_2...10412
FAILURE CODE [CB4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error_2...10414
FAILURE CODE [CB4152] SCR Temperature Sensor Datalink Timeout Error_2...10418
FAILURE CODE [CB4155] AdBlue/DEF Pump Heater Relay Voltage High Error_2...10422
FAILURE CODE [CB4156] AdBlue/DEF Pump Heater Relay Voltage Low Error_2...10425
FAILURE CODE [CB4157] AdBlue/DEF FCV Malfunction_2...10428
FAILURE CODE [CB4158] KDOC and KDPF Temperature Sensor Internal Circuit Error_2...10430
FAILURE CODE [CB4159] SCR Temperature Sensor Internal Circuit Error_2...10431
FAILURE CODE [CB4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error_2...10432
FAILURE CODE [CB4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error_2...10435
FAILURE CODE [CB4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error_2...10438
FAILURE CODE [CB4164] SCR Temperature Sensor ECU Voltage High Error_2...10440
FAILURE CODE [CB4165] SCR Temperature Sensor ECU Voltage Low Error_2...10443
FAILURE CODE [CB4166] SCR Temperature Sensor ECU High Temperature Error_2...10446
FAILURE CODE [CB4168] AdBlue/DEF Pump Heater ON Stuck Error_2...10447
FAILURE CODE [CB4169] AdBlue/DEF Pump Heater OFF Stuck Error_2...10451
FAILURE CODE [CB4171] AdBlue/DEF Pump Thawing Error_2...10454
FAILURE CODE [CB4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error_2...10458
FAILURE CODE [CB4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error_2...10461
FAILURE CODE [CB4259] KDOC and KDPF Temperature Sensor Power Interrupt Error_2...10466
FAILURE CODE [CB4261] SCR Temperature Sensor Power Interrupt Error_2...10469
FAILURE CODE [CB4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error_2...10472
FAILURE CODE [CB4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error_2...10475
FAILURE CODE [CB4658] AdBlue/DEF Flow Low Error_2...10478
FAILURE CODE [CB4952] System Operating Lamp Short Circuit (Engine Controller)_2...10482
FAILURE CODE [CB5115] AdBlue/DEF Line Heater 1 Voltage Low Error_2...10484
FAILURE CODE [CB5383] Ash Accumulation High Error_2...10487
FAILURE CODE [D162KA] Horn Relay Output Open Circuit (AJSS specification)...10489
FAILURE CODE [D162KA] Horn Relay Output Open Circuit (steering wheel specification)...10491
FAILURE CODE [D162KB] Horn Relay Output Ground Fault (AJSS specification)...10493
FAILURE CODE [D162KB] Horn Relay Output Ground Fault (steering wheel specification)...10495
FAILURE CODE [D162KY] Horn Relay Output Hot Short Circuit (AJSS specification)...10497
FAILURE CODE [D162KY] Horn Relay Output Hot Short Circuit (steering wheel specification)...10499
FAILURE CODE [D191KA] Neutral Relay Output Open Circuit...10501
FAILURE CODE [D191KB] Neutral Relay Output Ground Fault...10504
FAILURE CODE [D191KY] Neutral Relay Output Hot Short Circuit...10507
FAILURE CODE [D192KA] ECSS Solenoid Open Circuit...10509
FAILURE CODE [D192KB] ECSS Solenoid Ground Fault...10511
FAILURE CODE [D192KY] ECSS Solenoid Hot Short Circuit...10513
FAILURE CODE [D19JKZ] Personal Code Relay Open Circuit or Short Circuit...10514
FAILURE CODE [D1E6KA] Parking Brake Relay Open Circuit...10516
FAILURE CODE [D1E6KB] Parking Brake Relay Ground Fault...10518
FAILURE CODE [D1E6KY] Parking Brake Relay Hot Short Circuit...10520
FAILURE CODE [D5ZHKA] Key SW C Terminal Signal Open Circuit or Ground Fault...10522
FAILURE CODE [D5ZHKB] Key SW C Terminal Signal Short Circuit...10524
FAILURE CODE [D5ZHKZ] Key SW C Terminal Signal Open Circuit or Short Circuit...10526
FAILURE CODE [D5ZHL6] Key SW C Terminal Signal Mismatch...10529
FAILURE CODE [D5ZMLD] Engine Power Mode Selection SW Ground Fault...10531
FAILURE CODE [D862KA] GPS Antenna Open Circuit...10533
FAILURE CODE [DA80L4] Auto Grease System Abnormality...10534
FAILURE CODE [DAF0KT] Monitor Nonvolatile Memory Abnormality...10536
FAILURE CODE [DAF0MB] Monitor ROM Abnormality...10537
FAILURE CODE [DAF0MC] Monitor Malfunction...10538
FAILURE CODE [DAF3KK] Main Power Voltage Low Error (Monitor)...10539
FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit...10541
FAILURE CODE [DAFDKB] 12V Power Output Hot Short Circuit or Ground Fault (Monitor)...10542
FAILURE CODE [DAFGMC] GPS Module Malfunction...10544
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor)...10545
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor)...10547
FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Monitor)...10549
FAILURE CODE [DAQ0KK] Main Power Voltage Low Error (T/M Controller)...10550
FAILURE CODE [DAQ0KT] Read Only Memory Abnormality (T/M Controller)...10553
FAILURE CODE [DAQ0MC] T/M Controller Malfunction...10554
FAILURE CODE [DAQ1KA] Key SW ACC Signal Open Circuit (T/M Controller)...10555
FAILURE CODE [DAQ2KK] Solenoid Power Voltage Low Error (T/M Controller)...10557
FAILURE CODE [DAQ4KB] Self-holding Relay Output Ground Fault (T/M Controller)...10560
FAILURE CODE [DAQ9KQ] Model Selection Signal Mismatch (T/M Controller)...10562
FAILURE CODE [DAQLKA] System Operating Lamp Open Circuit (T/M Controller)...10563
FAILURE CODE [DAQLKB] System Operating Lamp Short Circuit (T/M Controller)...10565
FAILURE CODE [DAQQKR] CAN2 Defective Communication (T/M Controller)...10567
FAILURE CODE [DAQRKR] CAN1 Defective Communication (T/M Controller)...10568
FAILURE CODE [DAQRMA] Option Selection Mismatch (T/M Controller)...10569
FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C)...10570
FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C ECU)...10571
FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine Controller)...10572
FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine Controller)...10580
FAILURE CODE [DB90KK] Main Power Voltage Low Error (W/E Controller)...10585
FAILURE CODE [DB90KT] Read Only Memory Abnormality (W/E Controller)...10588
FAILURE CODE [DB90MC] W/E Controller Malfunction...10589
FAILURE CODE [DB91KA] Key SW ACC Signal Open Circuit (W/E Controller)...10590
FAILURE CODE [DB92KK] Solenoid Power Voltage Low Error (W/E Controller)...10592
FAILURE CODE [DB95KX] Failure of 5V Power Source 1...10595
FAILURE CODE [DB96KX] 5V Sensor Power Supply 2 Voltage out of Range (W/E Controller)...10597
FAILURE CODE [DB97KX] 24V Power Supply System Abnormality (BBC)...10600
FAILURE CODE [DB99KQ] Model Selection Signal Mismatch (W/E Controller)...10601
FAILURE CODE [DB9LKA] System Operating Lamp Open Circuit (W/E Controller)...10602
FAILURE CODE [DB9LKB] System Operating Lamp Short Circuit (W/E Controller)...10604
FAILURE CODE [DB9QKR] CAN 2 Defective Communication (W/E Controller)...10606
FAILURE CODE [DB9RKR] CAN 1 Defective Communication (W/E Controller)...10607
FAILURE CODE [DB9RMA] Option Selection Mismatch (W/E Controller)...10608
FAILURE CODE [DBE5KX] 5V Sensor Power Supply Voltage out of Range (T/M Controller)...10609
FAILURE CODE [DBE6KX] 24V Sensor Power Supply Ground Fault (T/M Controller)...10611
FAILURE CODE [DBV0MC] KOMTRAX Plus Malfunction...10613
FAILURE CODE [DBV1KK] Controller Power Supply Voltage Low (KOMTRAX Plus)...10614
FAILURE CODE [DBV5KX] 5V Sensor Power Supply 1 System Abnormality (KOMTRAX Plus)...10616
FAILURE CODE [DBV6KX] 24V Sensor Power Supply System Abnormality (KOMTRAX Plus)...10618
FAILURE CODE [DBV7KX] 12V Sensor Power Supply System Abnormality (KOMTRAX Plus)...10620
FAILURE CODE [DBV8KX] 5V Sensor Power Supply 2 System Abnormality (KOMTRAX Plus)...10621
FAILURE CODE [DBVLKA] System Operating Lamp Open Circuit (KOMTRAX Plus)...10622
FAILURE CODE [DBVLKB] System Operating Lamp Short Circuit (KOMTRAX Plus)...10624
FAILURE CODE [DBVQK4] CAN2 Defective Communication 2 (KOMTRAX Plus)...10626
FAILURE CODE [DBVQKR] CAN2 Defective Communication (KOMTRAX Plus)...10627
FAILURE CODE [DBVRKR] CAN1 Defective Communication (KOMTRAX Plus)...10628
FAILURE CODE [DBVVKR] LAN 1 Defective Communication...10629
FAILURE CODE [DBVWKR] LAN 2 Defective Communication...10630
FAILURE CODE [DD1ALD] Remote Positioner Set SW Ground Fault...10631
FAILURE CODE [DDA8KB] Throttle Lock Set SW Hot Short Circuit...10633
FAILURE CODE [DDA9KB] Throttle Lock Resume or Deceleration SW Ground Fault...10635
FAILURE CODE [DDAAL6] Engine Shutdown Secondary SW Signal Open Circuit...10637
FAILURE CODE [DDB6L4] Neutrizer Signal Mismatch...10639
FAILURE CODE [DDD1LD] Bucket Positioner Set SW Ground Fault...10642
FAILURE CODE [DDDBKA] Traction Setting Dial Open Circuit...10644
FAILURE CODE [DDDBKB] Traction Setting Dial Ground Fault...10646
FAILURE CODE [DDE5KA] Secondary S/T Activity Signal Ground Fault...10648
FAILURE CODE [DDK4KA] AJSS FNR SW Signal Input Disconnection...10649
FAILURE CODE [DDK4KB] AJSS FNR SW Signal Plural Input...10652
FAILURE CODE [DDK5L4] J/S Shift Up and Shift Down SW Signal Hot Short Circuit...10654
FAILURE CODE [DDK6KA] Directional Lever Signal Open Circuit...10656
FAILURE CODE [DDK6KB] Directional Lever Signal Short Circuit...10659
FAILURE CODE [DDNRKY] W/E Lock SW Hot Short Circuit...10662
FAILURE CODE [DDP5KA] S/T Lock Lever Pressure SW Open Circuit...10664
FAILURE CODE [DDW9LD] Kickdown SW Ground Fault...10666
FAILURE CODE [DDWLLD] T/M Shift Hold SW Ground Fault...10668
FAILURE CODE [DF10KA] T/M Shift Lever Input Signal Open Circuit...10670
FAILURE CODE [DF10KB] T/M Shift Lever Input Signal Short Circuit...10674
FAILURE CODE [DGE5KA] Ambient Air Temperature Sensor Open Circuit or Hot Short Circuit...10677
FAILURE CODE [DGE5KB] Ambient Air Temperature Sensor Ground Fault...10679
FAILURE CODE [DGF1KA] T/M Oil Temperature Sensor Open Circuit...10681
FAILURE CODE [DGF1KB] T/M Oil Temperature Sensor Ground Fault...10683
FAILURE CODE [DGH2KX] Hydraulic Oil Temperature Sensor Input Signal Out of Range...10685
FAILURE CODE [DGR2KB] Brake Oil Temperature Sensor Ground Fault (Rear)...10687
FAILURE CODE [DGR2KZ] Brake Oil Temperature Sensor Open Circuit or Hot Short Circuit (Rear)...10689
FAILURE CODE [DGR4KB] Brake Oil Temperature Sensor Ground Fault (Front)...10691
FAILURE CODE [DGR4KZ] Brake Oil Temperature Sensor Open Circuit or Hot Short Circuit (Front)...10693
FAILURE CODE [DGT1KA] T/C Oil Temperature Sensor Open Circuit...10695
FAILURE CODE [DGT1KB] T/C Oil Temperature Sensor Ground Fault...10697
FAILURE CODE [DGT4KA] Exhaust Temperature Sensor Open Circuit or Ground Fault...10699
FAILURE CODE [DGT4KY] Exhaust Temperature Sensor Hot Short Circuit...10701
FAILURE CODE [DH21KA] Loader Pump Pressure Sensor Open Circuit or Ground Fault...10703
FAILURE CODE [DH21KY] Loader Pump Pressure Sensor Signal Hot Short Circuit...10706
FAILURE CODE [DHA4KA] Air Cleaner Clogging Sensor Open Circuit...10708
FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Frozen...10710
FAILURE CODE [DHABMA] KDPF Differential Pressure Sensor Frozen_2...10711
FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen...10712
FAILURE CODE [DHADMA] KDPF Outlet Pressure Sensor Frozen_2...10713
FAILURE CODE [DHPCKA] Boom Cylinder Bottom Pressure Sensor Open Circuit...10714
FAILURE CODE [DHPCKY] Boom Cylinder Bottom Pressure Sensor Hot Short Circuit...10716
FAILURE CODE [DHPDKA] Boom Cylinder Head Pressure Sensor Open Circuit...10718
FAILURE CODE [DHPDKY] Boom Cylinder Head Pressure Sensor Hot Short Circuit...10720
FAILURE CODE [DHQ2KX] Main Flow Selector Valve Pressure Sensor Input Signal Out of Range...10722
FAILURE CODE [DHT2L6] T/M Oil Filter Clogging Sensor Open Circuit...10724
FAILURE CODE [DHT5KX] T/C Oil Pressure Sensor Input Signal Out of Range (Inlet)...10725
FAILURE CODE [DHT7KX] T/C Oil Pressure Sensor Input Signal Out of Range (Outlet)...10728
FAILURE CODE [DHT8KA] S/T Oil Pressure Sensor Open Circuit or Ground Fault...10731
FAILURE CODE [DHT8KY] Steering Oil Pressure Sensor Signal Hot Short Circuit...10734
FAILURE CODE [DHTBKA] Mod/C Pressure Sensor Open Circuit...10736
FAILURE CODE [DHTBKB] Mod/C Pressure Sensor Hot Short Circuit...10738
FAILURE CODE [DHU2KA] Brake Oil Pressure Sensor Signal Open Circuit or Ground Fault (Front)...10740
FAILURE CODE [DHU2KY] Brake Oil Pressure Sensor Signal Hot Short Circuit (Front)...10742
FAILURE CODE [DHU3KA] Brake Oil Pressure Sensor Signal Open Circuit or Ground Fault (Rear)...10744
FAILURE CODE [DHU3KY] Brake Oil Pressure Sensor Signal Hot Short Circuit (Rear)...10746
FAILURE CODE [DJF1KA] Fuel Level Sensor Open Circuit...10748
FAILURE CODE [DK30KA] AJSS Lever Potentio Sensor Signal Open Circuit or Ground Fault...10750
FAILURE CODE [DK30KY] AJSS Lever Potentio Sensor Signal Hot Short Circuit...10752
FAILURE CODE [DK55KA] Directional Lever Potentiometer Open Circuit or Groud Fault...10754
FAILURE CODE [DK55KY] Directional Lever Potentiometer Hot Short Circuit...10757
FAILURE CODE [DK55L5] Directional Lever SW and Potentiometer Input Signal Mispatch...10759
FAILURE CODE [DK59KA] Boom Lever Potentiometer Open Circuit or Ground Fault (Main)...10760
FAILURE CODE [DK59KY] Boom Lever Potentiometer Hot Short Circuit (Main)...10765
FAILURE CODE [DK59L8] Boom Lever Potentiometer Main or Sub Signal Abnormality...10769
FAILURE CODE [DK5AKA] Boom Lever Potentiometer Open Circuit or Ground Fault (Sub)...10774
FAILURE CODE [DK5AKY] Boom Lever Potentiometer Hot Short Circuit (Sub)...10778
FAILURE CODE [DK5BKA] Bucket Lever Potentiometer Open Circuit or Ground Fault (Main)...10782
FAILURE CODE [DK5BKY] Bucket Lever Potentiometer Hot Short Circuit (Main)...10786
FAILURE CODE [DK5BL8] Bucket Lever Potentiometer Main or Sub Signal Abnormality...10790
FAILURE CODE [DK5CKA] Bucket Lever Potentiometer Open Circuit or Ground Fault (Sub)...10795
FAILURE CODE [DK5CKY] Bucket Lever Potentiometer Hot Short Circuit (Sub)...10799
FAILURE CODE [DK5DKA] 3rd Lever Potentiometer Open Circuit or Ground Fault (Main)...10803
FAILURE CODE [DK5DKY] 3rd Lever Potentiometer Hot Short Circuit (Main)...10806
FAILURE CODE [DK5DL8] 3rd Lever Potentiometer Main or Sub Signal Abnormality...10809
FAILURE CODE [DK5EKA] 3rd Lever Potentiometer Open Circuit or Ground Fault (Sub)...10813
FAILURE CODE [DK5EKY] 3rd Lever Potentiometer Hot Short Circuit (Sub)...10816
FAILURE CODE [DKA0KA] Boom Angle Sensor Open Circuit or Ground Fault...10819
FAILURE CODE [DKA0KY] Boom Angle Sensor Hot Short Circuit...10822
FAILURE CODE [DKA0L0] Boom Angle Sensor Dislocation...10825
FAILURE CODE [DKA1KA] Bucket Angle Sensor Open Circuit or Ground Fault...10828
FAILURE CODE [DKA1KY] Bucket Angle Sensor Hot Short Circuit...10831
FAILURE CODE [DKD0KA] AJSS Frame Potentio Sensor Signal Open Circuit or Ground Fault...10833
FAILURE CODE [DKD0KY] AJSS Frame Potentio Sensor Signal Hot Short Circuit...10835
FAILURE CODE [DKD0L8] AJSS Frame Potentio Sensor Signal Deviation...10837
FAILURE CODE [DLFAKA] Mod/C Speed Sensor Open Circuit...10838
FAILURE CODE [DLFALC] Mod/C Speed Sensor System Abnormality...10840
FAILURE CODE [DLM3KA] Radiator Fan Speed Sensor Open Circuit or Hot Short Circuit...10842
FAILURE CODE [DLM3LC] Radiator Fan Speed Sensor Signal Abnormality...10844
FAILURE CODE [DLT3KA] T/M Output Speed Sensor Open Circuit (Main)...10846
FAILURE CODE [DLT3LC] T/M Output Speed Sensor Signal Abnormality (Main)...10848
FAILURE CODE [DLT4KB] T/M Output Speed Sensor Ground Fault (Sub)...10850
FAILURE CODE [DLT4KX] T/M Output Speed Sensor Open Circuit (Sub)...10852
FAILURE CODE [DPQ1KR] LIN Defective Communication (Switch Panel)...10854
FAILURE CODE [DPQ2KR] LIN Defective Communication (LED Unit)...10857
FAILURE CODE [DPQ3KR] LIN Defective Communication (Rearview Monitor)...10860
FAILURE CODE [DSJ0KR] CAN 2 Defective Communication (Meter Unit)...10863
FAILURE CODE [DT22KB] W/E Lock SW Indicator Ground Fault...10866
FAILURE CODE [DV00KB] Buzzer Output Ground Fault...10868
FAILURE CODE [DW2BKA] Main Flow Selector Solenoid Open Circuit...10870
FAILURE CODE [DW2BKB] Main Flow Selector Solenoid Ground Fault...10872
FAILURE CODE [DW2BKY] Main Flow Selector Solenoid Hot Short Circuit...10874
FAILURE CODE [DW2BL1] Main Flow Selector Valve Release Trouble...10876
FAILURE CODE [DW2BLH] Main Flow Selector Valve Operation Malfunction...10878
FAILURE CODE [DW4PKA] Boom RAISE EPC Solenoid Open Circuit...10879
FAILURE CODE [DW4PKB] Boom RAISE EPC Solenoid Ground Fault...10881
FAILURE CODE [DW4PKY] Boom RAISE EPC Solenoid Hot Short Circuit...10883
FAILURE CODE [DW4QKA] Boom LOWER EPC Solenoid Open Circuit...10885
FAILURE CODE [DW4QKB] Boom LOWER EPC Solenoid Ground Fault...10887
FAILURE CODE [DW4QKY] Boom LOWER EPC Solenoid Hot Short Circuit...10889
FAILURE CODE [DW4RKA] Bucket TILT EPC Solenoid Open Circuit...10891
FAILURE CODE [DW4RKB] Bucket TILT EPC Solenoid Ground Fault...10893
FAILURE CODE [DW4RKY] Bucket TILT EPC Solenoid Hot Short Circuit...10895
FAILURE CODE [DW4SKA] Bucket DUMP EPC Solenoid Open Circuit...10897
FAILURE CODE [DW4SKB] Bucket DUMP EPC Solenoid Ground Fault...10899
FAILURE CODE [DW4SKY] Bucket DUMP EPC Solenoid Hot Short Circuit...10901
FAILURE CODE [DW7BKA] Radiator Fan Reverse Solenoid Open Circuit...10903
FAILURE CODE [DW7BKB] Radiator Fan Reverse Solenoid Ground Fault...10905
FAILURE CODE [DW7BKY] Radiator Fan Reverse Solenoid Hot Short Circuit...10907
FAILURE CODE [DWM1KA] W/E Neutral Lock Solenoid Open Circuit...10909
FAILURE CODE [DWM1KB] W/E Neutral Lock Solenoid Ground Fault...10911
FAILURE CODE [DWM1KY] W/E Neutral Lock Solenoid Hot Short Circuit...10913
FAILURE CODE [DWN6KA] Boom Detent Solenoid Open Circuit...10915
FAILURE CODE [DWN6KB] Boom Detent Solenoid Ground Fault...10917
FAILURE CODE [DWN6KY] Boom Detent Solenoid Hot Short Circuit...10919
FAILURE CODE [DWN8KA] Bucket Detent Solenoid Open Circuit...10921
FAILURE CODE [DWN8KB] Bucket Detent Solenoid Ground Fault...10923
FAILURE CODE [DWN8KY] Bucket Detent Solenoid Hot Short Circuit...10925
FAILURE CODE [DWNFKA] Mod/C Cut Off Nullification Solenoid Open Circuit...10927
FAILURE CODE [DWNFKB] Mod/C Cut Off Nullification Solenoid Ground Fault...10929
FAILURE CODE [DWNFKY] Mod/C Cut Off Nullification Solenoid Hot Short Circuit...10931
FAILURE CODE [DX16KA] Radiator Fan Pump EPC Solenoid Open Circuit...10933
FAILURE CODE [DX16KB] Radiator Fan Pump EPC Solenoid Ground Fault...10935
FAILURE CODE [DX16KY] Radiator Fan Pump EPC Solenoid Hot Short Circuit...10937
FAILURE CODE [DXA1KA] Loader Pump EPC Solenoid Open Circuit...10939
FAILURE CODE [DXA1KB] Loader Pump EPC Solenoid Ground Fault...10941
FAILURE CODE [DXA1KY] Loader Pump EPC Solenoid Hot Short Circuit...10943
FAILURE CODE [DXF0KA] AJSS EPC Solenoid Open Circuit...10944
FAILURE CODE [DXF0KB] AJSS EPC Solenoid Ground Fault...10946
FAILURE CODE [DXF0KY] AJSS EPC Solenoid Hot Short Circuit...10948
FAILURE CODE [DXH1KA] ECMV Solenoid Open Circuit (Lockup Clutch)...10950
FAILURE CODE [DXH1KB] ECMV Solenoid Ground Fault (Lockup Clutch)...10952
FAILURE CODE [DXH1KY] ECMV Solenoid Hot Short Circuit (Lockup Clutch)...10954
FAILURE CODE [DXH4KA] ECMV Solenoid Open Circuit (1st Clutch)...10956
FAILURE CODE [DXH4KB] ECMV Solenoid Ground Fault (1st Clutch)...10958
FAILURE CODE [DXH4KY] ECMV Solenoid Hot Short Circuit (1st Clutch)...10960
FAILURE CODE [DXH5KA] ECMV Solenoid Open Circuit (2nd Clutch)...10962
FAILURE CODE [DXH5KB] ECMV Solenoid Ground Fault (2nd Clutch)...10964
FAILURE CODE [DXH5KY] ECMV Solenoid Hot Short Circuit (2nd Clutch)...10966
FAILURE CODE [DXH6KA] ECMV Solenoid Open Circuit (3rd Clutch)...10968
FAILURE CODE [DXH6KB] ECMV Solenoid Ground Fault (3rd Clutch)...10970
FAILURE CODE [DXH6KY] ECMV Solenoid Hot Short Circuit (3rd Clutch)...10972
FAILURE CODE [DXH7KA] ECMV Solenoid Open Circuit (Reverse Clutch)...10974
FAILURE CODE [DXH7KB] ECMV Solenoid Ground Fault (Reverse Clutch)...10976
FAILURE CODE [DXH7KY] ECMV Solenoid Hot Short Circuit (Reverse Clutch)...10978
FAILURE CODE [DXH8KA] ECMV Solenoid Open Circuit (Forward Clutch)...10980
FAILURE CODE [DXH8KB] ECMV Solenoid Ground Fault (Forward Clutch)...10982
FAILURE CODE [DXH8KY] ECMV Solenoid Hot Short Circuit (Forward Clutch)...10984
FAILURE CODE [DXHHKA] ECMV Solenoid Open Circuit (4th Clutch)...10986
FAILURE CODE [DXHHKB] ECMV Solenoid Ground Fault (4th Clutch)...10988
FAILURE CODE [DXHHKY] ECMV Solenoid Hot Short Circuit (4th Clutch)...10990
FAILURE CODE [DXHJKA] 3rd Spool Extend EPC Solenoid Open Circuit...10992
FAILURE CODE [DXHJKB] 3rd Spool Extend EPC Solenoid Ground Fault...10994
FAILURE CODE [DXHJKY] 3rd Spool Extend EPC Solenoid Hot Short Circuit...10996
FAILURE CODE [DXHKKA] 3rd Spool Retract EPC Solenoid Open Circuit...10998
FAILURE CODE [DXHKKB] 3rd Spool Retract EPC Solenoid Ground Fault...11000
FAILURE CODE [DXHKKY] 3rd Spool Retract EPC Solenoid Hot Short Circuit...11002
FAILURE CODE [DXHPKA] ECMV Solenoid Output Open Circuit (Mod/C)...11004
FAILURE CODE [DXHPKB] ECMV Solenoid Output Ground Fault (Mod/C)...11006
FAILURE CODE [DXHPKY] ECMV Solenoid Output Hot Short Circuit (Mod/C)...11008
FAILURE CODE [DXHPMA] ECMV Solenoid (Mod/C) Malfunction...11010
FAILURE CODE [DXHPMB] ECMV Solenoid (Mod/C) Deterioration...11012
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...11014
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...11014
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK...11023
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK...11026
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP...11029
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING...11031
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING...11034
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)...11036
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY...11038
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL...11040
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL...11043
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL...11046
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY...11048
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION...11051
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL...11054
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY...11057
E-16 REAR VIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS...11058
E-17 REAR VIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY...11061
E-18 REAR VIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED...11064
E-19 NIGHT LIGHTING LAMP OF REAR VIEW MONITOR IS ABNORMAL...11067
E-20 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP...11069
E-21 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP...11071
E-22 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION...11073
E-23 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...11077
E-24 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...11079
E-25 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL...11081
E-26 TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP...11083
E-27 INDICATION OF HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT...11084
E-28 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL...11086
E-29 ALARM BUZZER DOES NOT SOUND...11087
E-30 ALARM BUZZER DOES NOT STOP SOUNDING...11089
E-31 KICKDOWN DOES NOT WORK WHEN KICKDOWN SWITCH IS TURNED ON...11090
E-32 HOLD SWITCH DOES NOT WORK WHEN IT IS PRESSED...11092
E-33 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED...11094
E-34 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE NORMALLY WHEN ENGINE POWER MODE SELECTOR SWITCH IS OPERATED...11098
E-35 FLOW OF LOADER PUMP DOES NOT INCREASE FROM THE MINIMUM RATE...11100
E-36 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED...11101
E-37 HORN DOES NOT SOUND...11103
E-38 HORN DOES NOT STOP SOUNDING...11106
E-39 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS...11108
E-40 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT...11110
E-41 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT...11114
E-42 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT...11118
E-43 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT...11120
E-44 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT...11122
E-45 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT...11126
E-46 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT...11130
E-47 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT...11133
E-48 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT...11137
E-49 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED...11139
E-50 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT...11142
E-51 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND...11144
E-52 FRONT WIPER DOES NOT OPERATE...11146
E-53 REAR WIPER DOES NOT OPERATE...11150
E-54 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY...11153
E-55 WINDOW WASHER DOES NOT OPERATE...11156
E-56 KOMTRAX Plus SYSTEM DOES NOT OPERATE NORMALLY...11159
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...11160
FAILURE MODE AND CAUSE TABLE...11160
H-1 MACHINE DOES NOT START...11182
H-2 LOCKUP IS NOT RELEASED...11185
H-3 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE...11186
H-4 TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADABILITY IS LOW, OR GEAR SPEED DOES NOT SHIFT...11187
H-5 LARGE SHOCK IS MADE WHEN MACHINE MOVES OFF OR GEAR IS SHIFTED...11190
H-6 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED...11193
H-7 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH...11196
H-8 MACHINE DOES NOT TURN (FOR STEERING WHEEL SPEC)...11198
H-9 MACHINE DOES NOT TURN (AJSS SPECIFICATION)...11200
H-10 TURNING RESPONSE IS POOR (FOR STEERING WHEEL SPEC)...11202
H-11 TURNING RESPONSE IS POOR (AJSS SPECIFICATION)...11204
H-12 STEERING WHEEL IS HEAVY TO OPERATE...11206
H-13 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (FOR STEERING WHEEL SPEC)...11207
H-14 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (AJSS SPECIFICATION)...11209
H-15 TURNING RADIUS DIFFERS BETWEEN RIGHT AND LEFT TURNS...11211
H-16 WHEEL BRAKES DO NOT WORK OR ARE WEAK...11212
H-17 WHEEL BRAKES ARE NOT RELEASED OR DRAG...11214
H-18 PARKING BRAKE DOES NOT WORK OR IT IS WEAK...11215
H-19 PARKING BRAKE IS NOT RELEASED OR DRAGS...11216
H-20 BOOM DOES NOT RISE...11218
H-21 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE...11220
H-22 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT...11222
H-23 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND...11223
H-24 HYDRAULIC DRIFT OF BOOM IS LARGE...11224
H-25 BOOM MOVES UP AND DOWN DURING OPERATION...11225
H-26 BUCKET DOES NOT TILT BACK...11226
H-27 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE...11228
H-28 BUCKET DECELERATES DURING TILT-BACK OPERATION...11230
H-29 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND...11231
H-30 HYDRAULIC DRIFT OF BUCKET IS LARGE...11232
H-31 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD)...11233
H-32 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE...11234
H-33 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS...11235
H-34 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS...11236
H-35 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES...11238
H-36 E.C.S.S. (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES...11239
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)...11240
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN...11241
TROUBLESHOOTING OF ENGINE (S-MODE)...11242
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...11242
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION...11243
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT...11244
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)...11245
S-4 ENGINE STARTABILITY IS POOR...11246
S-5 ENGINE DOES NOT PICK UP SMOOTHLY...11248
S-6 ENGINE STOPS DURING OPERATION...11250
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE...11252
S-8 ENGINE LACKS POWER...11253
S-9 KDPF GETS CLOGGED IN A SHORT TIME...11255
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE...11257
S-11 OIL BECOMES CONTAMINATED QUICKLY...11258
S-12 FUEL CONSUMPTION IS EXCESSIVE...11259
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)...11260
S-14 OIL PRESSURE DROPS...11261
S-15 FUEL MIXES INTO ENGINE OIL...11263
S-16 WATER MIXES INTO ENGINE OIL (MILKY)...11264
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...11265
S-18 UNUSUAL NOISE IS HEARD...11266
S-19 VIBRATION IS EXCESSIVE...11267
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT...11268
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY...11269
S-22 ACTIVE REGENERATION TAKES TIME...11271
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION...11272
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE...11273
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)...11275
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)...11276
50 DISASSEMBLY AND ASSEMBLY...11277
CONTENTS...11278
ABBREVIATION LIST...11283
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY...11288
HOW TO READ THIS MANUAL...11288
COATING MATERIALS LIST...11290
SPECIAL TOOLS LIST...11295
SKETCHES OF SPECIAL TOOLS...11312
ENGINE AND COOLING SYSTEM...11318
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY...11318
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY...11318
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY...11329
REMOVE AND INSTALL INJECTOR ASSEMBLY...11343
METHOD FOR REMOVING INJECTOR ASSEMBLY...11344
METHOD FOR INSTALLING INJECTOR ASSEMBLY...11355
REMOVE AND INSTALL FUEL DOSER ASSEMBLY...11368
METHOD FOR REMOVING FUEL DOSER ASSEMBLY...11368
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY...11369
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY...11371
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY...11372
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY...11418
REMOVE AND INSTALL EGR VALVE ASSEMBLY...11475
METHOD FOR REMOVING EGR VALVE ASSEMBLY...11475
METHOD FOR INSTALLING EGR VALVE ASSEMBLY...11476
REMOVE AND INSTALL EGR COOLER ASSEMBLY...11477
METHOD FOR REMOVING EGR COOLER ASSEMBLY...11477
METHOD FOR INSTALLING EGR COOLER ASSEMBLY...11486
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY...11495
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY...11495
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY...11496
REMOVE AND INSTALL ALTERNATOR BELT...11497
METHOD FOR REMOVING ALTERNATOR BELT...11497
METHOD FOR INSTALLING ALTERNATOR BELT...11498
REMOVE AND INSTALL RADIATOR ASSEMBLY...11500
METHOD FOR REMOVING RADIATOR ASSEMBLY...11500
METHOD FOR INSTALLING RADIATOR ASSEMBLY...11502
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY...11505
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY...11505
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY...11506
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY...11509
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY...11509
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY...11510
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY...11512
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY...11512
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY...11513
REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY...11516
METHOD FOR REMOVING POWER TRAIN OIL COOLER ASSEMBLY...11516
METHOD FOR INSTALLING POWER TRAIN OIL COOLER ASSEMBLY...11518
REMOVE AND INSTALL ENGINE ASSEMBLY...11521
METHOD FOR REMOVING ENGINE ASSEMBLY...11521
METHOD FOR INSTALLING ENGINE ASSEMBLY...11534
REMOVE AND INSTALL ENGINE FRONT OIL SEAL...11547
METHOD FOR REMOVING ENGINE FRONT OIL SEAL...11547
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL...11550
REMOVE AND INSTALL ENGINE REAR OIL SEAL...11554
METHOD FOR REMOVING ENGINE REAR OIL SEAL...11554
METHOD FOR INSTALLING ENGINE REAR OIL SEAL...11555
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY...11560
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY...11560
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY...11562
REMOVE AND INSTALL FUEL TANK ASSEMBLY...11565
METHOD FOR REMOVING FUEL TANK ASSEMBLY...11565
METHOD FOR INSTALLING FUEL TANK ASSEMBLY...11568
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY...11571
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY...11571
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY...11576
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...11581
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...11581
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...11586
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR...11591
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR...11591
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR...11591
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER...11593
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER...11593
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER...11593
REMOVE AND INSTALL KDPF ASSEMBLY...11594
METHOD FOR REMOVING KDPF ASSEMBLY...11594
METHOD FOR INSTALLING KDPF ASSEMBLY...11597
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY...11600
METHOD FOR DISASSEMBLING KDPF ASSEMBLY...11600
METHOD FOR ASSEMBLING KDPF ASSEMBLY...11605
REMOVE AND INSTALL SCR ASSEMBLY...11611
METHOD FOR REMOVING SCR ASSEMBLY...11611
METHOD FOR INSTALLING SCR ASSEMBLY...11613
REMOVE AND INSTALL KDPF, SCR ASSEMBLY...11616
METHOD FOR REMOVING KDPF, SCR ASSEMBLY...11616
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY...11622
REMOVE AND INSTALL KCCV ASSEMBLY...11627
METHOD FOR REMOVING KCCV ASSEMBLY...11627
METHOD FOR INSTALLING KCCV ASSEMBLY...11628
REMOVE AND INSTALL KVGT ASSEMBLY...11630
METHOD FOR REMOVING KVGT ASSEMBLY...11630
METHOD FOR INSTALLING KVGT ASSEMBLY...11635
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE...11640
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE...11640
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE...11643
REMOVE AND INSTALL AdBlue/DEF INJECTOR...11648
METHOD FOR REMOVING AdBlue/DEF INJECTOR...11648
METHOD FOR INSTALLING AdBlue/DEF INJECTOR...11651
REMOVE AND INSTALL AdBlue/DEF PUMP...11656
METHOD FOR REMOVING AdBlue/DEF PUMP...11656
METHOD FOR INSTALLING AdBlue/DEF PUMP...11659
REMOVE AND INSTALL AdBlue/DEF HOSE...11662
METHOD FOR REMOVING AdBlue/DEF HOSE...11662
METHOD FOR INSTALLING AdBlue/DEF HOSE...11670
REMOVE AND INSTALL AIR CLEANER ASSEMBLY...11680
METHOD FOR REMOVING AIR CLEANER ASSEMBLY...11680
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY...11681
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY...11683
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY...11683
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY...11684
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...11686
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY...11686
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY...11687
POWER TRAIN...11689
REMOVE AND INSTALL DAMPER ASSEMBLY...11689
METHOD FOR REMOVING DAMPER ASSEMBLY...11689
METHOD FOR INSTALLING DAMPER ASSEMBLY...11690
DISASSEMBLING AND ASSEMBLE DAMPER ASSEMBLY...11692
METHOD FOR DISASSEMBLING DAMPER ASSEMBLY...11692
METHOD FOR ASSEMBLING DAMPER ASSEMBLY...11694
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...11697
METHOD FOR REMOVING TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...11697
METHOD FOR INSTALLING TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...11704
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY...11711
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY...11712
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY...11727
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY...11746
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY...11747
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY...11762
DISASSEMBLE AND ASSEMBLE TRANSFER ASSEMBLY...11783
METHOD FOR DISASSEMBLING TRANSFER ASSEMBLY...11783
METHOD FOR ASSEMBLING TRANSFER ASSEMBLY...11792
REMOVE AND INSTALL PARKING BRAKE ASSEMBLY...11804
METHOD FOR REMOVING PARKING BRAKE ASSEMBLY...11804
METHOD FOR INSTALLING PARKING BRAKE ASSEMBLY...11805
DISASSEMBLE AND ASSEMBLE PARKING BRAKE ASSEMBLY...11807
METHOD FOR DISASSEMBLING PARKING BRAKE ASSEMBLY...11807
METHOD FOR ASSEMBLING PARKING BRAKE ASSEMBLY...11811
REMOVE AND INSTALL FRONT AXLE ASSEMBLY...11817
METHOD FOR REMOVING FRONT AXLE ASSEMBLY...11817
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY...11819
REMOVE AND INSTALL REAR AXLE ASSEMBLY...11821
METHOD FOR REMOVING REAR AXLE ASSEMBLY...11821
METHOD FOR INSTALLING REAR AXLE ASSEMBLY...11823
REMOVE AND INSTALL CENTER SUPPORT...11826
METHOD FOR REMOVING CENTER SUPPORT...11826
METHOD FOR INSTALLING CENTER SUPPORT...11827
DISASSEMBLE AND ASSEMBLE OF CENTER SUPPORT...11829
METHOD FOR DISASSEMBLING CENTER SUPPORT...11829
METHOD FOR ASSEMBLING CENTER SUPPORT...11830
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY...11833
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY...11834
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY...11841
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY...11853
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY...11854
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY...11857
REMOVE AND INSTALL FINAL DRIVE CARRIER ASSEMBLY...11863
METHOD FOR REMOVING FINAL DRIVE CARRIER ASSEMBLY...11863
METHOD FOR INSTALLING FINAL DRIVE CARRIER ASSEMBLY...11865
DISASSEMBLE AND ASSEMBLE FINAL DRIVE CARRIER ASSEMBLY...11867
METHOD FOR DISASSEMBLING FINAL DRIVE CARRIER ASSEMBLY...11867
METHOD FOR ASSEMBLING FINAL DRIVE CARRIER ASSEMBLY...11867
REMOVE AND INSTALL FRONT FINAL DRIVE AND BRAKE ASSEMBLY...11869
METHOD FOR REMOVING FRONT FINAL DRIVE AND BRAKE ASSEMBLY...11869
METHOD FOR INSTALLING FRONT FINAL DRIVE AND BRAKE ASSEMBLY...11870
STEERING SYSTEM...11872
REMOVE AND INSTALL STEERING VALVE ASSEMBLY...11872
METHOD FOR REMOVING STEERING VALVE ASSEMBLY...11872
METHOD FOR INSTALLING STEERING VALVE ASSEMBLY...11873
BRAKE SYSTEM...11876
DISASSEMBLE AND ASSEMBLE BRAKE ASSEMBLY...11876
METHOD FOR DISASSEMBLING BRAKE ASSEMBLY...11876
METHOD FOR ASSEMBLING BRAKE ASSEMBLY...11879
UNDERCARRIAGE AND FRAME...11883
REMOVE AND INSTALL CENTER HINGE PIN...11883
METHOD FOR REMOVING CENTER HINGE PIN...11884
METHOD FOR INSTALLING CENTER HINGE PIN...11887
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...11893
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY...11893
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY...11894
HYDRAULIC SYSTEM...11896
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...11896
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY...11896
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY...11899
REMOVE AND INSTALL WORK EQUIPMENT PUMP ASSEMBLY...11903
METHOD FOR REMOVING WORK EQUIPMENT PUMP ASSEMBLY...11903
METHOD FOR INSTALLING WORK EQUIPMENT PUMP ASSEMBLY...11905
REMOVE AND INSTALL POWER TRAIN PUMP ASSEMBLY...11908
METHOD FOR REMOVING POWER TRAIN PUMP ASSEMBLY...11908
METHOD FOR INSTALLING POWER TRAIN PUMP ASSEMBLY...11910
REMOVE AND INSTALL STEERING PUMP AND COOLING FAN PUMP ASSEMBLY...11912
METHOD FOR REMOVING STEERING PUMP AND COOLING FAN PUMP ASSEMBLY...11912
METHOD FOR INSTALLING STEERING PUMP AND COOLING FAN PUMP ASSEMBLY...11915
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY...11918
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY...11918
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY...11921
WORK EQUIPMENT...11924
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY...11924
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY...11924
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY...11928
DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLY...11936
METHOD FOR DISASSEMBLING HYDRAULIC CYLINDER ASSEMBLY...11937
METHOD FOR ASSEMBLING HYDRAULIC CYLINDER ASSEMBLY...11939
CAB AND ITS ATTACHMENTS...11944
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY...11944
METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY...11944
METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY...11952
REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS)...11961
METHOD FOR REMOVING OPERATOR'S CAB GLASS (ADHERED GLASS)...11961
METHOD FOR INSTALLING OPERATOR'S CAB GLASS (ADHERED GLASS)...11962
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY...11971
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY...11971
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY...11975
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY...11979
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY...11979
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY...11983
REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY...11987
METHOD FOR REMOVING OPERATOR'S SEAT ASSEMBLY...11987
METHOD FOR INSTALLING OPERATOR'S SEAT ASSEMBLY...11989
REMOVE AND INSTALL WORK EQUIPMENT CONTROL LEVER...11991
METHOD FOR REMOVING WORK EQUIPMENT CONTROL LEVER...11991
METHOD FOR INSTALLING WORK EQUIPMENT CONTROL LEVER...11993
REMOVE AND INSTALL SEAT BELT...11996
METHOD FOR REMOVING SEAT BELT...11996
METHOD FOR INSTALLING SEAT BELT...11996
ELECTRICAL SYSTEM...11998
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...11998
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY...11998
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY...11999
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY...12003
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY...12003
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY...12004
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY...12007
METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY...12007
METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY...12008
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY...12011
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY...12011
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY...12012
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY...12015
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY...12015
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY...12016
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR...12018
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR...12018
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR...12018
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR...12019
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR...12019
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR...12020
REMOVE AND INSTALL SCR TEMPERATURE SENSOR...12022
METHOD FOR REMOVING SCR TEMPERATURE SENSOR...12022
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR...12024
REMOVE AND INSTALL KOMTRAX Plus CONTROLLER ASSEMBLY...12026
METHOD FOR REMOVING KOMTRAX Plus CONTROLLER ASSEMBLY...12026
METHOD FOR INSTALLING KOMTRAX Plus CONTROLLER ASSEMBLY...12027
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY...12028
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY...12028
METHOD FOR NSTALLING KOMTRAX TERMINAL ASSEMBLY...12028
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY...12030
METHOD FOR REMOVING WIRELESS LAN UNIT ASSEMBLY...12030
METHOD FOR NSTALLING WIRELESS LAN UNIT ASSEMBLY...12031
60 MAINTENANCE STANDARD...12033
CONTENTS...12034
ABBREVIATION LIST...12035
ENGINE AND COOLING SYSTEM...12040
MAINTENANCE STANDARD OF ENGINE MOUNT...12040
MAINTENANCE STANDARD OF DAMPER...12041
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP...12043
MAINTENANCE STANDARD OF SERVO VALVE OF BRAKE AND COOLING FAN PUMP...12044
MAINTENANCE STANDARD OF COOLING FAN MOTOR...12046
POWER TRAIN...12049
MAINTENANCE STANDARD OF DRIVE SHAFT...12049
MAINTENANCE STANDARD OF CENTER SUPPORT...12050
MAINTENANCE STANDARD OF TRANSMISSION MOUNT...12052
MAINTENANCE STANDARD OF TORQUE CONVERTER...12053
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV...12059
MAINTENANCE STANDARD OF MODULATION CLUTCH ECMV...12060
MAINTENANCE STANDARD OF TRANSMISSION...12061
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE...12069
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND, 3RD, 4TH CLUTCH ECMV...12071
MAINTENANCE STANDARD OF TORQUE CONVERTER REGULATOR VALVE...12072
MAINTENANCE STANDARD OF MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE...12073
MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION RELIEF VALVE...12076
MAINTENANCE STANDARD OF FRONT AXLE...12077
MAINTENANCE STANDARD OF REAR AXLE...12081
MAINTENANCE STANDARD OF FRONT DIFFERENTIAL...12085
MAINTENANCE STANDARD OF REAR DIFFERENTIAL...12089
MAINTENANCE STANDARD OF FINAL DRIVE...12093
STEERING SYSTEM...12095
MAINTENANCE STANDARD OF STEERING COLUMN...12095
MAINTENANCE STANDARD OF STEERING PUMP...12096
MAINTENANCE STANDARD OF STEERING VALVE...12098
MAINTENANCE STANDARD OF STEERING CYLINDER...12099
MAINTENANCE STANDARD OF DIVERTER VALVE...12101
MAINTENANCE STANDARD OF SECONDARY STEERING PUMP...12102
BRAKE SYSTEM...12103
MAINTENANCE STANDARD OF BRAKE VALVE...12103
MAINTENANCE STANDARD OF SLACK ADJUSTER...12107
MAINTENANCE STANDARD OF BRAKE...12108
MAINTENANCE STANDARD OF PARKING BRAKE...12110
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE...12112
MAINTENANCE STANDARD OF BRAKE COOLING PUMP...12113
UNDERCARRIAGE AND FRAME...12114
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN...12114
HYDRAULIC SYSTEM...12119
MAINTENANCE STANDARD OF HYDRAULIC TANK...12119
MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP...12120
MAINTENANCE STANDARD OF POWER TRAIN CHARGE DUPLEX PUMP...12123
MAINTENANCE STANDARD OF CONTROL VALVE...12124
WORK EQUIPMENT...12137
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE...12137
MAINTENANCE STANDARD OF BUCKET...12141
MAINTENANCE STANDARD OF LIFT CYLINDER...12143
MAINTENANCE STANDARD OF BUCKET CYLINDER...12144
80 APPENDIX...12145
CONTENTS...12146
ABBREVIATION LIST...12148
AIR CONDITIONER SYSTEM...12153
PRECAUTIONS FOR REFRIGERANT...12153
AIR CONDITIONER COMPONENT...12154
SPECIFICATIONS OF AIR CONDITIONER...12156
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE...12157
OUTLINE OF REFRIGERATION CYCLE...12158
COMPONENT PARTS OF AIR CONDITIONER SYSTEM...12160
AIR CONDITIONER UNIT...12160
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT...12160
FUNCTION OF AIR CONDITIONER UNIT...12162
COMPONENT PARTS OF AIR CONDITIONER UNIT...12164
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT...12165
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT...12165
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT...12165
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT...12165
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...12166
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...12166
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...12166
FUNCTION OF DUAL PRESSURE SWITCH...12167
AIR CONDITIONER CONTROLLER...12168
STRUCTURE OF AIR CONDITIONER CONTROLLER...12168
COMPRESSOR...12169
STRUCTURE OF COMPRESSOR...12169
SPECIFICATIONS OF COMPRESSOR...12169
FUNCTION OF COMPRESSOR...12170
CONDENSER...12171
STRUCTURE OF CONDENSER...12171
SPECIFICATIONS OF CONDENSER...12171
FUNCTION OF CONDENSER...12171
SENSORS FOR AIR CONDITIONER SYSTEM...12173
STRUCTURE OF SUNLIGHT SENSOR...12173
FUNCTION OF SUNLIGHT SENSOR...12173
STRUCTURE OF AMBIENT TEMPERATURE SENSOR...12173
FUNCTION OF AMBIENT TEMPERATURE SENSOR...12173
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER...12175
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER...12177
AIR CONDITIONER SYSTEM DIAGRAM...12179
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER...12179
FUNCTION OF AIR CONDITIONER CONTROLLER...12181
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS...12182
TESTING AIR LEAKAGE (DUCT)...12186
METHOD FOR TESTING AIR LEAKAGE (DUCT)...12186
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION...12188
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR...12190
TEST VENT (MODE) CHANGEOVER...12191
METHOD FOR TESTING VENT (MODE) CHANGEOVER...12191
TESTING FRESH/RECIRC AIR CHANGEOVER...12192
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER...12192
TEST SUNLIGHT SENSOR...12193
METHOD FOR TESTING SUNLIGHT SENSOR...12193
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT...12194
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT...12194
TEST RELAYS...12195
METHOD FOR TESTING RELAYS...12195
AIR CONDITIONER TROUBLESHOOTING CHART 1...12196
AIR CONDITIONER TROUBLESHOOTING CHART 2...12197
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...12200
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit...12202
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit...12203
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit...12204
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit...12206
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit...12208
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit...12209
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit...12210
FAILURE CODE [879EMC] Ventilation Damper Malfunction...12212
FAILURE CODE [879FMC] Air Mix Damper Malfunction...12213
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range...12214
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)...12216
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)...12218
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)...12221
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER...12223
TROUBLESHOOTING USING GAUGE PRESSURE...12225
CONNECTION OF SERVICE TOOL...12227
METHOD FOR CONNECTING SERVICE TOOL...12227
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS...12228
HANDLE COMPRESSOR OIL...12230
METHOD FOR REPLACING DESICCANT...12232
90 CIRCUIT DIAGRAMS...12235
CONTENTS...12236
ABBREVIATION LIST...12237
HYDRAULIC CIRCUIT DIAGRAM...12242
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM...12242
HYDRAULIC CIRCUIT DIAGRAM (FOR AJSS SPEC)...12247
HYDRAULIC CIRCUIT DIAGRAM (FOR STEERING WHEEL SPEC)...12248
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM...12249
ELECTRICAL CIRCUIT DIAGRAM...12250
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM...12250
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/8)...12254
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/8)...12255
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/8)...12256
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/8)...12257
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/8)...12258
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/8)...12259
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/8)...12260
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/8)...12261
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (1/7)...12262
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (2/7)...12263
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (3/7)...12264
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (4/7)...12265
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (5/7)...12266
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (6/7)...12267
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (7/7)...12268
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL SPEC) (1/7)...12269
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL SPEC) (2/7)...12270
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL SPEC) (3/7)...12271
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL SPEC) (4/7)...12272
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL SPEC) (5/7)...12273
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL SPEC) (6/7)...12274
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL SPEC) (7/7)...12275
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE (1/2)...12276
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE (2/2)...12277
INDEX...12278
TEN00002-02 - Wheel Loader GALEO WA600-3 Operation & Maintenance Manual...12308
COVER...12308
FOREWORD...12309
FOREWORD...12310
SAFETY INFORMATION...12313
INTRODUCTION...12315
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...12315
NECESSARY INFORMATION...12316
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...12316
ENGINE SERIAL NO. PLATE AND POSITION...12316
POSITION OF SERVICE METER...12317
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...12317
CONTENTS...12318
SAFETY...12321
SAFETY...12322
SAFETY LABELS...12324
LOCATION OF SAFETY LABELS...12325
GENERAL PRECAUTIONS...12331
SAFETY RULES...12331
IF ABNORMALITIES ARE FOUND...12331
CLOTHING AND PERSONAL PROTECTIVE ITEMS...12331
FIRE EXTINGUISHER AND FIRST AID KIT...12331
SAFETY FEATURES...12331
KEEP MACHINE CLEAN...12332
INSIDE OPERATOR'S COMPARTMENT...12332
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...12332
HANDRAILS AND STEPS...12333
MOUNTING AND DISMOUNTING...12333
NO PEOPLE ON ATTACHMENTS...12333
DO NOT GET CAUGHT IN ARTICULATED PORTION...12334
PREVENTION OF BURNS...12334
FIRE PREVENTION...12335
ACTION IF FIRE OCCURS...12336
WINDOW WASHER LIQUID...12336
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)...12336
PRECAUTIONS FOR ATTACHMENTS, OPTIONS...12336
UNAUTHORIZED MODIFICATION...12336
SAFETY AT WORKSITE...12337
WORKING ON LOOSE GROUND...12337
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...12338
ENSURE GOOD VISIBILITY...12338
PRECAUTIONS RELATED TO VENTILATION EXHAUST GAS...12338
CHECKING SIGNALMAN'S SIGNALS AND SIGNS...12339
EMERGENCY EXIT FROM OPERATOR'S CAB...12339
BE CAREFUL ABOUT ASBESTOS DUST...12339
PRECAUTIONS FOR OPERATION...12340
STARTING ENGINE...12340
CHECKS BEFORE STARTING ENGINE...12340
PRECAUTIONS WHEN STARTING...12340
PRECAUTIONS IN COLD AREAS...12341
OPERATION...12342
CHECKS BEFORE OPERATION...12342
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...12342
PRECAUTIONS WHEN TRAVELING...12343
TRAVELING ON SLOPES...12344
PROHIBITED OPERATIONS...12345
PRECAUTIONS WHEN OPERATING...12345
METHODS OF USING BRAKE...12346
OPERATE CAREFULLY ON SNOW...12346
PARKING MACHINE ...12347
TRANSPORTATION...12348
LOADING AND UNLOADING...12348
SHIPPING...12348
BATTERY...12349
BATTERY HAZARD PREVENTION...12349
STARTING WITH BOOSTER CABLES...12350
TOWING...12351
PRECAUTIONS FOR MAINTENANCE...12352
WARNING TAG ...12352
KEEP WORK PLACE CLEAN AND TIDY...12352
APPOINT LEADER WHEN WORKING WITH OTHERS...12352
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...12353
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...12354
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF...12354
PROPER TOOLS...12355
WORK EQUIPMENT SUPPORT...12355
ACCUMULATOR...12355
PERSONNEL...12355
ATTACHMENTS ...12356
NOISE...12356
PRECAUTIONS WHEN USING HAMMER ...12356
REPAIR WELDING ...12356
REMOVING BATTERY TERMINAL ...12356
PRECAUTIONS WITH HIGH-PRESSURE OIL...12357
HANDLING HIGH-PRESSURE HOSES...12357
WASTE MATERIALS ...12357
MAINTENANCE OF AIR CONDITIONER...12357
COMPRESSED AIR...12358
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ...12358
PRECAUTIONS WITH TIRES...12359
HANDLING TIRES...12359
PRECAUTIONS WHEN STORING TIRES...12359
OPERATION...12360
GENERAL VIEW...12361
GENERAL VIEW OF MACHINE...12361
GENERAL VIEW OF CONTROLS AND GAUGES...12362
EXPLANATION OF COMPONENTS...12364
MACHINE MONITOR...12364
SWITCHES...12378
CONTROL LEVERS, PEDALS...12386
STEERING COLUMN TILT LEVER...12390
CAP WITH LOCK...12391
SAFETY BAR...12392
TOWING PIN...12392
GREASE PUMP...12393
BACKUP ALARM...12393
DUST INDICATOR...12393
CAB DOOR OPEN LOCK...12394
TOOL BOX...12394
OIL FILLER LOCATION...12394
FUSE...12394
SLOW BLOW FUSE...12396
LUNCH BOX TRAY...12396
POWER OUTLET...12396
OPERATION...12397
CHECK BEFORE STARTING ENGINE, ADJUST...12397
STARTING ENGINE...12412
OPERATIONS AND CHECKS AFTER STARTING ENGINE...12414
STOPPING ENGINE...12416
CHECK AFTER STOPPING ENGINE...12416
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...12417
TURNING...12422
OPERATION OF WORK EQUIPMENT...12423
WORK POSSIBLE USING WHEEL LOADER...12425
PRECAUTIONS FOR OPERATION...12431
ADJUSTING WORK EQUIPMENT POSTURE...12433
REMOVAL AND INSTALLATION OF THE BUCKET...12435
PARKING MACHINE...12439
CHECKS AFTER COMPLETION OF OPERATION...12441
LOCKING...12441
HANDLING THE TIRES...12442
TRANSPORTATION...12444
TRANSPORTATION PROCEDURE...12444
LOADING, UNLOADING WORK...12444
METHOD OF SECURING MACHINE...12444
METHOD OF LIFTING MACHINE...12446
COLD WEATHER OPERATION...12449
PRECAUTIONS FOR LOW TEMPERATURE...12449
PRECAUTIONS AFTER COMPLETION OF WORK...12450
AFTER COLD WEATHER...12451
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...12451
LONG-TERM STORAGE...12452
BEFORE STORAGE...12452
DURING STORAGE...12452
AFTER STORAGE...12452
TROUBLESHOOTING...12453
WHEN MACHINE RUNS OUT OF FUEL...12453
METHOD OF TOWING MACHINE...12455
IF BATTERY IS DISCHARGED...12458
OTHER TROUBLE...12461
MAINTENANCE...12465
GUIDES TO MAINTENANCE...12466
OUTLINES OF SERVICE...12468
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...12468
OUTLINE OF ELECTRIC SYSTEM...12471
WEAR PARTS...12472
WEAR PARTS LIST...12472
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...12473
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...12474
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...12475
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...12476
TORQUE LIST...12476
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...12477
SAFETY CRITICAL PARTS...12477
MAINTENANCE SCHEDULE CHART...12478
MAINTENANCE SCHEDULE CHART...12478
SERVICE PROCEDURE...12480
INITIAL 250 HOURS SERVICE...12480
INITIAL 2000 HOURS SERVICE...12480
CHECK INJECTOR SETTING LOAD, ADJUST...12480
WHEN REQUIRED...12481
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...12481
CLEAN INSIDE OF COOLING SYSTEM...12483
CHECK TRANSMISSION OIL LEVEL, ADD OIL...12486
CHECK AXLE OIL LEVEL, ADD OIL...12487
CLEAN AXLE CASE BREATHER...12488
CLEAN AIR CONDITIONER CONDENSER...12488
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...12489
CLEAN RADIATOR FINS...12489
CHECK ELECTRICAL INTAKE AIR HEATER...12489
REPLACE BUCKET TEETH...12490
LUBRICATING...12491
CHECK AIR CONDITIONER...12491
REPLACE SLOW BLOW FUSE...12492
BLEEDING AIR FROM HYDRAULIC TANK...12493
REPLACE FAN BELT, ADJUST AUTO-TENSIONER...12493
SELECTION AND INSPECTION OF TIRES...12495
CHECK BEFORE STARTING...12497
EVERY 50 HOURS SERVICE...12498
DRAIN WATER, SEDIMENT FROM FUEL TANK...12498
EVERY 100 HOURS SERVICE...12499
LUBRICATE REAR AXLE PIVOT PIN...12499
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...12499
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...12500
EVERY 250 HOURS SERVICE...12501
CHECK BATTERY ELECTROLYTE LEVEL...12501
CHECK PARKING BRAKE...12502
CHECK ALTERNATOR BELT TENSION, ADJUST...12503
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...12504
CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN...12504
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...12505
LUBRICATING...12506
EVERY 500 HOURS SERVICE...12509
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...12509
REPLACE FUEL FILTER CARTRIDGE...12511
REPLACE TRANSMISSION OIL FILTER ELEMENT...12512
LUBRICATE CENTER DRIVE SHAFT SPLINE...12513
CHECK FAN BELT FOR WEAR ...12513
EVERY 1000 HOURS SERVICE...12514
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...12514
CLEAN TRANSMISSION CASE BREATHER...12515
CLEAN RADIATOR SUB-TANK BREATHER...12515
LUBRICATING...12516
CHECK TIGHTENING PARTS OF TURBOCHARGER...12518
CLEAN FUEL STRAINER...12518
REPLACE CORROSION RESISTOR CARTRIDGE...12518
EVERY 2000 HOURS SERVICE...12519
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...12519
REPLACE HYDRAULIC TANK BREATHER ELEMENT...12521
CHANGE AXLE OIL...12522
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...12523
CLEAN PPC CIRCUIT STRAINER...12523
CLEAN ENGINE BREATHER ELEMENT...12524
CHECK ALTERNATOR, STARTING MOTOR...12524
CHECK ENGINE VALVE CLEARANCE, ADJUST...12524
CHECK BRAKE DISC WEAR...12524
CLEAN AND CHECK TURBOCHARGER...12524
CHECK ACCUMULATOR FUNCTION...12525
CHECK ACCUMULATOR GAS PRESSURE...12525
EVERY 4000 HOURS SERVICE...12526
CHECK WATER PUMP...12526
CHECK VIBRATION DAMPER...12526
CHECK FAN PULLEY AND TENSION PULLEY...12526
CHECK AIR CONDITIONER COMPRESSOR, ADJUST...12526
SPECIFICATIONS...12527
SPECIFICATIONS...12528
ATTACHMENTS, OPTIONS...12529
SELECTING BUCKET AND TIRES...12530
HANDLING AUTO-GREASING SYSTEM...12531
METHOD OF OPERATING AUTO-GREASING SYSTEM...12531
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM...12536
HANDLING AUTOMATIC SHIFT SYSTEM...12537
METHOD OF OPERATION...12537
PRECAUTION WHEN CHANGING DIRECTION...12538
HANDLING E.C.S.S.(ELECTRONIC CONTROLLED SUSPENSION SYSTEM)...12539
STRUCTURE AND FUNCTION OF E.C.S.S...12539
METHOD OF OPERATING E.C.S.S...12539
PRECAUTIONS WHEN OPERATING E.C.S.S. SWITCH...12539
PRECAUTIONS WHEN HANDLING ACCUMULATOR...12540
REMOVAL OF E.C.S.S. PIPING...12540
HANDLING JOYSTICK STEERING SYSTEM...12541
STRUCTURE AND FUNCTION OF JOYSTICK STEERING...12541
OPERATION METHOD OF JOYSTICK STEERING SYSTEM...12545
PRECAUTIONS FOR STEERING WITH JOYSTICK...12547
ADJUSTMENT OF JOYSTICK CONSOLE...12548
HANDLING AIR-SUSPENSION SEAT...12549
SEAT ADJUSTMENT...12549
FAILURE DISPLAY ON MAIN MONITOR...12551
FAILURE CODE ON MAIN MONITOR...12551
FAILURE CODE ON AUTOMATIC SHIFT, E.C.S.S. AND JOYSTICK STEERING SYSTEM...12551
CAR RADIO...12552
EXPLANATION OF COMPONENTS...12552
METHOD OF USE...12555
PRECAUTIONS WHEN USING...12557
AM/FM RADIO-CASSETTE STEREO...12558
EXPLANATION OF COMPONENTS...12558
METHOD OF OPERATION...12563
PRECAUTIONS FOR USE...12565
AIR CONDITIONER...12566
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL...12566
METHOD OF OPERATION...12569
INDEX...12571
TEN00002-04 - Wheel Loader WA600-3 Operation & Maintenance Manual...12575
COVER...12575
FOREWORD...12576
FOREWORD...12577
SAFETY INFORMATION...12580
INTRODUCTION...12582
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...12582
NECESSARY INFORMATION...12583
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...12583
ENGINE SERIAL NO. PLATE AND POSITION...12583
POSITION OF SERVICE METER...12584
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...12584
CONTENTS...12585
SAFETY...12588
SAFETY...12589
SAFETY LABELS...12591
LOCATION OF SAFETY LABELS...12592
GENERAL PRECAUTIONS...12598
PRECAUTIONS FOR OPERATION...12607
STARTING ENGINE...12607
OPERATION...12609
TRANSPORTATION...12615
BATTERY...12616
TOWING...12618
PRECAUTIONS FOR MAINTENANCE...12619
PRECAUTIONS WITH TIRES...12626
OPERATION...12628
GENERAL VIEW...12629
GENERAL VIEW OF MACHINE...12629
GENERAL VIEW OF CONTROLS AND GAUGES...12630
EXPLANATION OF COMPONENTS...12632
MACHINE MONITOR...12632
SWITCHES...12646
CONTROL LEVERS, PEDALS...12654
STEERING COLUMN TILT LEVER...12658
CAP WITH LOCK...12659
SAFETY BAR...12660
TOWING PIN...12660
GREASE PUMP...12661
BACKUP ALARM...12661
DUST INDICATOR...12661
CAB DOOR OPEN LOCK...12662
TOOL BOX...12662
OIL FILLER LOCATION...12662
FUSE...12662
SLOW BLOW FUSE...12664
LUNCH BOX TRAY...12664
POWER OUTLET...12664
OPERATION...12665
CHECK BEFORE STARTING ENGINE, ADJUST...12665
STARTING ENGINE...12680
OPERATIONS AND CHECKS AFTER STARTING ENGINE...12682
STOPPING ENGINE...12684
CHECK AFTER STOPPING ENGINE...12684
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...12685
TURNING...12690
OPERATION OF WORK EQUIPMENT...12691
WORK POSSIBLE USING WHEEL LOADER...12693
PRECAUTIONS FOR OPERATION...12699
ADJUSTING WORK EQUIPMENT POSTURE...12701
REMOVAL AND INSTALLATION OF THE BUCKET...12703
PARKING MACHINE...12707
CHECKS AFTER COMPLETION OF OPERATION...12709
LOCKING...12709
HANDLING THE TIRES...12710
TRANSPORTATION...12712
TRANSPORTATION PROCEDURE...12712
LOADING, UNLOADING WORK...12712
METHOD OF SECURING MACHINE...12712
METHOD OF LIFTING MACHINE...12714
COLD WEATHER OPERATION...12717
PRECAUTIONS FOR LOW TEMPERATURE...12717
PRECAUTIONS AFTER COMPLETION OF WORK...12718
AFTER COLD WEATHER...12719
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...12719
LONG-TERM STORAGE...12720
BEFORE STORAGE...12720
DURING STORAGE...12720
AFTER STORAGE...12720
TROUBLESHOOTING...12721
WHEN MACHINE RUNS OUT OF FUEL...12721
METHOD OF TOWING MACHINE...12722
IF BATTERY IS DISCHARGED...12725
OTHER TROUBLE...12728
MAINTENANCE...12732
GUIDES TO MAINTENANCE...12733
OUTLINES OF SERVICE...12735
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...12735
OUTLINE OF ELECTRIC SYSTEM...12738
WEAR PARTS...12739
WEAR PARTS LIST...12739
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...12740
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...12741
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...12742
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...12743
TORQUE LIST...12743
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...12744
SAFETY CRITICAL PARTS...12744
MAINTENANCE SCHEDULE CHART...12745
MAINTENANCE SCHEDULE CHART...12745
SERVICE PROCEDURE...12747
INITIAL 250 HOURS SERVICE...12747
INITIAL 2000 HOURS SERVICE...12747
WHEN REQUIRED...12748
CHECK BEFORE STARTING...12764
EVERY 50 HOURS SERVICE...12765
EVERY 100 HOURS SERVICE...12766
EVERY 250 HOURS SERVICE...12767
EVERY 500 HOURS SERVICE...12775
EVERY 1000 HOURS SERVICE...12780
EVERY 2000 HOURS SERVICE...12787
EVERY 4000 HOURS SERVICE...12794
SPECIFICATIONS...12796
SPECIFICATIONS...12797
ATTACHMENTS, OPTIONS...12798
SELECTING BUCKET AND TIRES...12799
HANDLING AUTO-GREASING SYSTEM...12800
METHOD OF OPERATING AUTO-GREASING SYSTEM...12800
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM...12805
TROUBLESHOOTING...12805
HANDLING AUTOMATIC SHIFT SYSTEM...12806
METHOD OF OPERATION...12806
PRECAUTION WHEN CHANGING DIRECTION...12807
HANDLING E.C.S.S.(ELECTRONIC CONTROLLED SUSPENSION SYSTEM)...12808
STRUCTURE AND FUNCTION OF E.C.S.S...12808
METHOD OF OPERATING E.C.S.S...12808
PRECAUTIONS WHEN OPERATING E.C.S.S. SWITCH...12808
PRECAUTIONS WHEN HANDLING ACCUMULATOR...12809
REMOVAL OF E.C.S.S. PIPING...12809
HANDLING JOYSTICK STEERING SYSTEM...12810
STRUCTURE AND FUNCTION OF JOYSTICK STEERING...12810
OPERATION METHOD OF JOYSTICK STEERING SYSTEM...12814
PRECAUTIONS FOR STEERING WITH JOYSTICK...12816
ADJUSTMENT OF JOYSTICK CONSOLE...12817
HANDLING AIR-SUSPENSION SEAT...12818
SEAT ADJUSTMENT...12818
FAILURE DISPLAY ON MAIN MONITOR...12820
FAILURE CODE ON MAIN MONITOR...12820
FAILURE CODE ON AUTOMATIC SHIFT, E.C.S.S. AND JOYSTICK STEERING SYSTEM...12820
CAR RADIO...12821
EXPLANATION OF COMPONENTS...12821
METHOD OF USE...12824
PRECAUTIONS WHEN USING...12826
AM/FM RADIO-CASSETTE STEREO...12827
EXPLANATION OF COMPONENTS...12827
METHOD OF OPERATION...12832
PRECAUTIONS FOR USE...12834
AIR CONDITIONER...12835
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL...12835
METHOD OF OPERATION...12838
INDEX...12840
TEN00111-06 - Wheel Loader GALEO WA600-6 Operation & Maintenance Manual...12844
COVER...12844
FOREWORD...12845
FOREWORD...12846
SAFETY INFORMATION...12849
INTRODUCTION...12851
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...12851
VISIBILITY FROM OPERATOR'S SEAT...12852
NECESSARY INFORMATION...12853
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...12853
EPA REGULATIONS, ENGINE NUMBER PLATE...12853
POSITION OF SERVICE METER...12854
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...12854
CONTENTS...12855
SAFETY...12859
SAFETY...12860
SAFETY LABELS...12862
LOCATION OF SAFETY LABELS...12863
SAFETY LABELS...12864
GENERAL PRECAUTIONS...12871
SAFETY RULES...12871
IF ABNORMALITIES ARE FOUND...12871
CLOTHING AND PERSONAL PROTECTIVE ITEMS...12871
FIRE EXTINGUISHER AND FIRST AID KIT...12871
SAFETY FEATURES...12871
KEEP MACHINE CLEAN...12872
INSIDE OPERATOR'S COMPARTMENT...12872
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...12873
HANDRAILS AND STEPS...12874
PRECAUTIONS WHEN CLEANING CAB GLASS...12875
MOUNTING AND DISMOUNTING...12875
NO PEOPLE ON ATTACHMENTS...12875
DO NOT GET CAUGHT IN ARTICULATED PORTION...12875
PREVENTION OF BURNS...12876
FIRE PREVENTION...12877
ACTION IF FIRE OCCURS...12877
WINDOW WASHER LIQUID...12878
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)...12878
PRECAUTIONS FOR ATTACHMENTS, OPTIONS...12878
UNAUTHORIZED MODIFICATION...12878
SAFETY AT WORKSITE...12879
WORKING ON LOOSE GROUND...12879
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...12880
ENSURE GOOD VISIBILITY...12880
PRECAUTIONS RELATED TO VENTILATION EXHAUST GAS...12881
CHECKING SIGNALMAN'S SIGNALS AND SIGNS...12881
EMERGENCY EXIT FROM OPERATOR'S CAB...12881
BE CAREFUL ABOUT ASBESTOS DUST...12881
PRECAUTIONS FOR OPERATION...12882
STARTING ENGINE...12882
CHECKS BEFORE STARTING ENGINE...12882
PRECAUTIONS WHEN STARTING...12882
PRECAUTIONS IN COLD AREAS...12883
OPERATION...12884
CHECKS BEFORE OPERATION...12884
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...12884
PRECAUTIONS WHEN TRAVELING...12885
TRAVELING ON SLOPES...12886
PROHIBITED OPERATIONS...12887
PRECAUTIONS WHEN OPERATING...12888
METHODS OF USING BRAKE...12888
OPERATE CAREFULLY ON SNOW...12889
PARKING MACHINE...12890
TRANSPORTATION...12892
LOADING AND UNLOADING...12892
SHIPPING...12892
BATTERY...12893
BATTERY HAZARD PREVENTION...12893
STARTING WITH BOOSTER CABLES...12894
TOWING...12895
PRECAUTIONS FOR MAINTENANCE...12896
WARNING TAG...12896
KEEP WORK PLACE CLEAN AND TIDY...12896
APPOINT LEADER WHEN WORKING WITH OTHERS...12896
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...12897
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...12899
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF...12899
PROPER TOOLS...12900
ACCUMULATOR...12900
PERSONNEL...12900
ATTACHMENTS...12900
WORK UNDER THE MACHINE...12901
NOISE...12901
PRECAUTIONS WHEN USING HAMMER...12901
REPAIR WELDING...12901
REMOVING BATTERY TERMINAL...12901
PRECAUTIONS WITH HIGH-PRESSURE OIL...12902
PRECAUTIONS FOR HIGH-PRESSURE FUEL...12902
HANDLING HIGH-PRESSURE HOSES...12902
WASTE MATERIALS...12903
MAINTENANCE OF AIR CONDITIONER...12903
COMPRESSED AIR...12903
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...12903
PRECAUTIONS WITH TIRES...12904
HANDLING TIRES...12904
PRECAUTIONS WHEN STORING TIRES...12904
OPERATION...12905
GENERAL VIEW...12906
GENERAL VIEW OF MACHINE...12906
GENERAL VIEW OF CONTROLS AND GAUGES...12907
EXPLANATION OF COMPONENTS...12913
MACHINE MONITOR...12913
SWITCHES...12954
CONTROL LEVERS, PEDALS...12979
CAP WITH LOCK...12986
FRAME LOCK BAR...12988
TOWING PIN...12989
BACKUP ALARM...12989
OPENING CAB, WINDOW DOOR...12990
HANDLING CAB WIPER...12992
DUST INDICATOR...12992
FUSE...12993
CIRCUIT BREAKER...12995
SLOW BLOW FUSE...12996
LUNCH BOX TRAY...12996
TOOL BOX...12996
GREASE PUMP...12996
LOCATION OF FIRE EXTINGUISHER...12997
POWER OUTLET...12997
AM/FM RADIO-CASSETTE STEREO...12998
AIR CONDITIONER...13007
OPERATION...13022
CHECK BEFORE STARTING ENGINE, ADJUST...13022
STARTING ENGINE...13039
OPERATIONS AND CHECKS AFTER STARTING ENGINE...13041
STOPPING ENGINE...13044
CHECK AFTER STOPPING ENGINE...13044
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...13045
TURNING...13053
OPERATION OF WORK EQUIPMENT...13055
SEMI AUTO DIGGING OPERATIONS...13057
REMOTE POSITIONER...13058
WORK POSSIBLE USING WHEEL LOADER...13060
PRECAUTIONS FOR OPERATION...13080
REMOVAL AND INSTALLATION OF THE BUCKET...13083
PARKING MACHINE...13087
CHECKS AFTER COMPLETION OF OPERATION...13089
LOCKING...13089
HANDLING THE TIRES...13090
TRANSPORTATION...13093
TRANSPORTATION PROCEDURE...13093
LOADING, UNLOADING WORK...13093
METHOD OF SECURING MACHINE...13093
METHOD OF LIFTING MACHINE...13095
PRECAUTIONS WHEN DISASSEMBLY OR REASSEMBLING WORK EQUIPMENT...13098
COLD WEATHER OPERATION...13099
PRECAUTIONS FOR LOW TEMPERATURE...13099
PRECAUTIONS AFTER COMPLETION OF WORK...13100
AFTER COLD WEATHER...13100
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...13101
LONG-TERM STORAGE...13102
BEFORE STORAGE...13102
DURING STORAGE...13102
AFTER STORAGE...13102
TROUBLESHOOTING...13103
WHEN MACHINE RUNS OUT OF FUEL...13103
METHOD OF TOWING MACHINE...13104
IF BATTERY IS DISCHARGED...13108
METHOD FOR LOWERING WORK EQUIPMENT WHEN ENGINE HAS STOPPED...13112
OTHER TROUBLE...13113
MAINTENANCE...13117
GUIDES TO MAINTENANCE...13118
OUTLINES OF SERVICE...13120
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...13120
OUTLINE OF ELECTRIC SYSTEM...13124
WEAR PARTS...13125
WEAR PARTS LIST...13126
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...13127
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...13128
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...13130
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...13131
TORQUE LIST...13131
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...13133
SAFETY CRITICAL PARTS...13134
MAINTENANCE SCHEDULE CHART...13136
MAINTENANCE SCHEDULE CHART...13136
SERVICE PROCEDURE...13138
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)...13138
INITIAL 250 HOURS SERVICE...13138
WHEN REQUIRED...13139
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...13139
CLEAN INSIDE OF COOLING SYSTEM...13142
CHECK TRANSMISSION OIL LEVEL, ADD OIL...13146
CHECK AXLE OIL LEVEL, ADD OIL...13148
CLEAN AXLE CASE BREATHER...13149
CLEAN AIR CONDITIONER CONDENSER...13150
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...13150
CLEAN RADIATOR FINS...13151
REPLACE BUCKET TEETH...13156
LUBRICATING...13158
CHECK AIR CONDITIONER...13159
REPLACE SLOW BLOW FUSE...13160
BLEEDING AIR FROM HYDRAULIC TANK...13161
BLEEDING AIR FROM FUEL CIRCUIT...13163
CHECKING FUNCTION OF ACCUMULATOR...13166
SELECTION AND INSPECTION OF TIRES...13167
CHECK BEFORE STARTING...13169
EVERY 50 HOURS SERVICE...13170
DRAIN WATER, SEDIMENT FROM FUEL TANK...13170
EVERY 100 HOURS SERVICE...13171
LUBRICATING...13171
LUBRICATE REAR AXLE PIVOT PIN...13173
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...13174
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...13175
EVERY 250 HOURS SERVICE...13176
CHECK BATTERY ELECTROLYTE LEVEL...13176
CHECK PARKING BRAKE...13178
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...13178
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...13178
CHECKING FUNCTION OF ACCUMULATOR...13178
EVERY 500 HOURS SERVICE...13179
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...13179
REPLACE FUEL PRE-FILTER CARTRIDGE...13181
REPLACE FUEL MAIN FILTER CARTRIDGE...13183
REPLACE TRANSMISSION OIL FILTER ELEMENT...13184
REPLACE BRAKE OIL FILTER CARTRIDGE (IF EQUIPPED)...13185
CHECK, REPLACE COMPRESSOR DRIVE BELT FOR ALTERNATOR, AIR CONDITIONER...13186
EVERY 1000 HOURS SERVICE...13187
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...13187
CLEAN TRANSMISSION CASE BREATHER...13188
LUBRICATING...13189
REPLACE CORROSION RESISTOR CARTRIDGE (ONLY WHEN CORROSION RESISTOR CARTRIDGE IS USED)...13189
CHECK, GREASE COMPRESSOR DRIVE BELT TENSION PULLEY ASSEMBLY FOR ALTERNATOR, AIR CONDITIONER...13190
EVERY 2000 HOURS SERVICE...13191
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...13191
CLEAN HYDRAULIC TANK STRAINER...13193
REPLACE HYDRAULIC TANK BREATHER ELEMENT...13194
CHANGE AXLE OIL...13195
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...13196
CLEAN PPC CIRCUIT STRAINER...13196
CHECK ALTERNATOR...13197
CHECK ENGINE VALVE CLEARANCE, ADJUST...13197
CHECK BRAKE DISC WEAR...13197
CHECKING FUNCTION OF ACCUMULATOR...13197
CHECK BOOST PIPING CLAMPS...13197
CHANGE OIL FOR WORK EQUIPMENT PINS...13198
EVERY 4000 HOURS SERVICE...13199
CHECK WATER PUMP...13199
CHECK STARTING MOTOR...13199
CHECK AIR CONDITIONER COMPRESSOR, ADJUST...13199
LUBRICATING...13200
CHECK FOR LOOSE ENGINE HIGH-PRESSURE PIPING CLAMPS, HARDENING OF RUBBER...13202
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER...13203
EVERY 8000 HOURS SERVICE...13204
REPLACE ENGINE HIGH-PRESSURE PIPING CLAMPS...13204
REPLACE FUEL SPRAY PREVENTION CAP...13204
OVERHAUL STARTING MOTOR AND ALTERNATOR...13204
SPECIFICATIONS...13205
SPECIFICATIONS...13206
ATTACHMENTS, OPTIONS...13211
HANDLING STEERING WHEEL SPECIFICATION MACHINE...13212
EXPLANATION OF COMPONENTS...13212
FUNCTIONS OF STEERING WHEEL SPECIFICATION MACHINE...13222
SELECTING BUCKET AND TIRES...13232
STARTING IN COLD AREAS...13233
ELECTRIC HEATER...13233
HANDLING LOAD METER...13236
OUTLINE OF LOAD METER...13236
PRINCIPLE OF LOAD METER MEASUREMENT...13238
POINTS TO REMEMBER TO ENSURE HIGH ACCURACY...13239
USING LOAD METER...13241
HANDLING AUTO-GREASING SYSTEM...13269
METHOD OF OPERATING AUTO-GREASING SYSTEM...13269
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM...13276
TROUBLESHOOTING...13276
HANDLING QUICK COUPLER CONTROL SYSTEM...13277
EXPLANATION OF COMPONENTS...13277
FUNCTION AND METHOD OF OPERATION OF QUICK COUPLER SWITCH...13280
METHOD OF REMOVING AND INSTALLING ATTACHMENT...13282
INSPECTION AND MAINTENANCE...13287
METHOD OF TURNING BOTTOM FRONT WORKING LAMP ON/OFF...13288
HANDLING BATTERY DISCONNECTOR SWITCH...13289
EXPLANATION OF COMPONENTS...13289
HANDLING...13289
HANDLING STARTING AID CONNECTOR...13291
HANDLING REAR FENDER...13293
HANDLING...13293
HANDLING MACHINES EQUIPPED WITH VHMS...13294
VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED...13294
VHMS AND COMMUNICATIONS TERMINAL INSTALLED...13294
INDEX...13297
TEN00240-02 - Wheel Loader WA600-6 Operation & Maintenance Manual...13301
COVER...13301
FOREWORD...13303
BEFORE READING THIS MANUAL...13304
SAFETY INFORMATION...13307
INTRODUCTION...13308
USE OF MACHINE...13308
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...13308
VISIBILITY FROM OPERATOR'S SEAT...13309
NECESSARY INFORMATION...13310
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...13310
EPA REGULATIONS, ENGINE NUMBER PLATE...13310
POSITION OF SERVICE METER...13311
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...13311
CONTENTS...13312
SAFETY...13317
SAFETY...13318
SAFETY LABELS...13321
LOCATION OF SAFETY LABELS...13322
SAFETY LABELS...13323
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...13330
PRECAUTIONS BEFORE STARTING OPERATION...13330
ENSURING SAFE OPERATION...13330
UNDERSTANDING THE MACHINE...13330
PREPARATIONS FOR SAFE OPERATION...13330
PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT...13330
INSPECTING MACHINE...13330
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT...13330
KEEP MACHINE CLEAN...13331
PRECAUTIONS INSIDE OPERATOR'S COMPARTMENT...13331
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT...13331
IF ANY PROBLEM IS FOUND...13331
FIRE PREVENTION...13332
ACTION IF FIRE OCCURS...13332
PRECAUTIONS TO PREVENT FIRE...13332
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE...13333
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE...13333
NO JUMPING ON OR OFF MACHINE...13333
NO PEOPLE ON ATTACHMENTS...13334
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT...13334
PRECAUTIONS WHEN LEAVING MACHINE...13335
EMERGENCY EXIT FROM OPERATOR'S CAB...13335
PRECAUTIONS WHEN CLEANING CAB GLASS...13336
DO NOT GET CAUGHT IN ARTICULATING PORTION...13336
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...13336
UNAUTHORIZED MODIFICATION...13336
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...13337
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING...13337
PRECAUTIONS FOR OPERATION...13338
PRECAUTIONS FOR JOBSITE...13338
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS...13338
WORKING ON LOOSE GROUND...13338
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...13339
ENSURE GOOD VISIBILITY...13339
CHECKING SIGNS AND SIGNALMAN'S SIGNALS...13339
BEWARE OF ASBESTOS DUST...13340
STARTING ENGINE...13340
WARNING TAG...13340
INSPECTION AND MAINTENANCE BEFORE STARTING ENGINE ...13341
PRECAUTIONS WHEN STARTING ENGINE...13341
PRECAUTIONS IN COLD AREAS...13341
STARTING WITH BOOSTER CABLES...13342
STARTING WITH STARTING AID CONNECTOR (IF EQUIPPED)...13342
OPERATION...13343
CHECKS BEFORE OPERATION...13343
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...13343
PRECAUTIONS WHEN TRAVELING...13344
TRAVELING ON SLOPES...13345
METHOD OF USING BRAKES...13345
PRECAUTIONS WHEN OPERATING...13346
PROHIBITED OPERATIONS...13347
TRAVELING ON SNOW-COVERED OR FROZEN SURFACES...13347
PARKING MACHINE...13348
TRANSPORTATION...13350
LOADING AND UNLOADING...13350
TOWING...13351
PRECAUTIONS WHEN TOWING ...13351
PRECAUTIONS FOR MAINTENANCE...13352
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ...13352
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE ...13352
KEEP WORKPLACE CLEAN AND TIDY...13352
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE...13352
ONLY AUTHORIZED PERSONNEL...13352
APPOINT LEADER WHEN WORKING WITH OTHERS...13352
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE ...13353
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...13355
TURNING E.C.S.S. SWITCH OFF BEFORE CARRYING OUT INSPECTION AND MAINTENANCE...13355
INSTALLING, REMOVING, OR STORING ATTACHMENTS...13356
PRECAUTIONS WHEN WORKING AT HIGH PLACES...13356
PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT ...13356
PROPER TOOLS...13356
PRECAUTIONS FOR INSPECTION AND MAINTENANCE...13357
PRECAUTIONS WHEN WELDING...13357
HANDLING BATTERY...13357
PRECAUTIONS WHEN USING HAMMER...13358
PRECAUTIONS WITH HIGH-TEMPERATURE COOLANT...13358
PRECAUTIONS WITH HIGH-TEMPERATURE OIL...13359
PRECAUTIONS WITH HIGH-PRESSURE OIL...13360
PRECAUTIONS WITH HIGH-PRESSURE FUEL...13360
HANDLING HIGH-PRESSURE HOSES AND PIPING...13360
NOISE...13360
HANDLING ACCUMULATOR AND GAS SPRING ...13361
PRECAUTIONS WITH COMPRESSED AIR ...13361
MAINTENANCE OF AIR CONDITIONER...13361
DISPOSING OF WASTE MATERIALS...13361
METHOD OF SELECTING WINDOW WASHER FLUID...13361
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...13362
TIRES...13363
HANDLING TIRES...13363
PRECAUTIONS WHEN STORING TIRES...13364
OPERATION...13365
GENERAL VIEW...13366
GENERAL VIEW OF MACHINE...13366
GENERAL VIEW OF CONTROLS AND GAUGES...13367
EXPLANATION OF COMPONENTS...13373
MACHINE MONITOR...13373
SWITCHES...13414
CONTROL LEVERS, PEDALS...13439
CAP WITH LOCK...13446
FRAME LOCK BAR...13448
TOWING PIN...13449
BACKUP ALARM...13449
OPENING CAB, WINDOW DOOR...13450
HANDLING CAB WIPER...13452
DUST INDICATOR...13452
FUSE...13453
CIRCUIT BREAKER...13455
SLOW BLOW FUSE...13456
LUNCH BOX TRAY...13456
TOOL BOX...13456
GREASE PUMP...13456
LOCATION OF FIRE EXTINGUISHER...13457
POWER OUTLET...13457
AM/FM RADIO-CASSETTE STEREO...13458
AIR CONDITIONER...13467
OPERATION...13482
CHECK BEFORE STARTING ENGINE, ADJUST...13482
STARTING ENGINE...13500
OPERATIONS AND CHECKS AFTER STARTING ENGINE...13502
STOPPING ENGINE...13505
CHECK AFTER STOPPING ENGINE...13505
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...13506
TURNING...13514
OPERATION OF WORK EQUIPMENT...13516
SEMI AUTO DIGGING OPERATIONS...13518
REMOTE POSITIONER...13519
WORK POSSIBLE USING WHEEL LOADER...13521
PRECAUTIONS FOR OPERATION...13541
REMOVAL AND INSTALLATION OF THE BUCKET...13544
PARKING MACHINE...13548
CHECKS AFTER COMPLETION OF OPERATION...13550
LOCKING...13550
HANDLING THE TIRES...13551
TRANSPORTATION...13554
TRANSPORTATION PROCEDURE...13554
LOADING, UNLOADING WORK...13554
METHOD OF SECURING MACHINE...13554
METHOD OF LIFTING MACHINE...13556
PRECAUTIONS WHEN DISASSEMBLY OR REASSEMBLING WORK EQUIPMENT...13559
COLD WEATHER OPERATION...13560
PRECAUTIONS FOR LOW TEMPERATURE...13560
PRECAUTIONS AFTER COMPLETION OF WORK...13561
AFTER COLD WEATHER...13561
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...13562
LONG-TERM STORAGE...13563
BEFORE STORAGE...13563
DURING STORAGE...13563
AFTER STORAGE...13563
TROUBLESHOOTING...13564
WHEN MACHINE RUNS OUT OF FUEL...13564
METHOD OF TOWING MACHINE...13565
IF BATTERY IS DISCHARGED...13569
METHOD FOR LOWERING WORK EQUIPMENT WHEN ENGINE HAS STOPPED...13573
OTHER TROUBLE...13574
MAINTENANCE...13579
GUIDES TO MAINTENANCE...13580
OUTLINES OF SERVICE...13582
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...13582
OUTLINE OF ELECTRIC SYSTEM...13586
WEAR PARTS...13587
WEAR PARTS LIST...13588
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...13589
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...13590
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...13592
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...13593
TORQUE LIST...13593
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...13595
SAFETY CRITICAL PARTS...13596
MAINTENANCE SCHEDULE CHART...13598
MAINTENANCE SCHEDULE CHART...13598
SERVICE PROCEDURE...13600
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)...13600
INITIAL 250 HOURS SERVICE...13600
WHEN REQUIRED...13601
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...13601
CLEAN INSIDE OF COOLING SYSTEM...13604
CHECK TRANSMISSION OIL LEVEL, ADD OIL...13608
CHECK AXLE OIL LEVEL, ADD OIL...13610
CLEAN AXLE CASE BREATHER...13611
CLEAN AIR CONDITIONER CONDENSER...13612
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...13612
CLEAN RADIATOR FINS...13613
REPLACE BUCKET TEETH...13618
LUBRICATING...13620
CHECK AIR CONDITIONER...13621
REPLACE SLOW BLOW FUSE...13622
BLEEDING AIR FROM HYDRAULIC TANK...13623
BLEEDING AIR FROM FUEL CIRCUIT...13625
CHECKING FUNCTION OF ACCUMULATOR...13628
SELECTION AND INSPECTION OF TIRES...13629
CHECK BEFORE STARTING...13631
EVERY 50 HOURS SERVICE...13632
DRAIN WATER, SEDIMENT FROM FUEL TANK...13632
EVERY 100 HOURS SERVICE...13633
LUBRICATING...13633
LUBRICATE REAR AXLE PIVOT PIN...13635
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...13636
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...13637
EVERY 250 HOURS SERVICE...13638
CHECK BATTERY ELECTROLYTE LEVEL...13638
CHECK PARKING BRAKE...13640
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...13640
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...13640
CHECKING FUNCTION OF ACCUMULATOR...13641
EVERY 500 HOURS SERVICE...13642
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...13642
REPLACE FUEL PRE-FILTER CARTRIDGE...13644
REPLACE FUEL MAIN FILTER CARTRIDGE...13646
REPLACE TRANSMISSION OIL FILTER ELEMENT...13647
REPLACE BRAKE OIL FILTER CARTRIDGE (IF EQUIPPED)...13648
CHECK, REPLACE COMPRESSOR DRIVE BELT FOR ALTERNATOR, AIR CONDITIONER...13649
EVERY 1000 HOURS SERVICE...13650
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...13650
CLEAN TRANSMISSION CASE BREATHER...13651
REPLACE FUEL TANK BREATHER ELEMENT...13652
LUBRICATING...13653
REPLACE CORROSION RESISTOR CARTRIDGE (ONLY WHEN CORROSION RESISTOR CARTRIDGE IS USED)...13653
CHECK, GREASE COMPRESSOR DRIVE BELT TENSION PULLEY ASSEMBLY FOR ALTERNATOR, AIR CONDITIONER...13654
EVERY 2000 HOURS SERVICE...13655
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...13655
CLEAN HYDRAULIC TANK STRAINER...13657
REPLACE HYDRAULIC TANK BREATHER ELEMENT...13658
CHANGE AXLE OIL...13659
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...13660
CLEAN PPC CIRCUIT STRAINER...13660
CHECK ALTERNATOR...13661
CHECK ENGINE VALVE CLEARANCE, ADJUST...13661
CHECK BRAKE DISC WEAR...13661
CHECKING FUNCTION OF ACCUMULATOR...13661
CHECK BOOST PIPING CLAMPS...13661
CHANGE OIL FOR WORK EQUIPMENT PINS...13662
EVERY 4000 HOURS SERVICE...13663
CHECK WATER PUMP...13663
CHECK STARTING MOTOR...13663
CHECK AIR CONDITIONER COMPRESSOR, ADJUST...13663
LUBRICATING...13664
CHECK FOR LOOSE ENGINE HIGH-PRESSURE PIPING CLAMPS, HARDENING OF RUBBER...13666
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER...13667
EVERY 8000 HOURS SERVICE...13668
REPLACE ENGINE HIGH-PRESSURE PIPING CLAMPS...13668
REPLACE FUEL SPRAY PREVENTION CAP...13668
OVERHAUL STARTING MOTOR AND ALTERNATOR...13668
SPECIFICATIONS...13669
SPECIFICATIONS...13670
ATTACHMENTS, OPTIONS...13675
HANDLING STEERING WHEEL SPECIFICATION MACHINE...13676
EXPLANATION OF COMPONENTS...13676
FUNCTIONS OF STEERING WHEEL SPECIFICATION MACHINE...13686
SELECTING BUCKET AND TIRES...13696
STARTING IN COLD AREAS...13697
ELECTRIC HEATER...13697
HANDLING LOAD METER...13701
OUTLINE OF LOAD METER...13701
PRINCIPLE OF LOAD METER MEASUREMENT...13703
POINTS TO REMEMBER TO ENSURE HIGH ACCURACY...13704
USING LOAD METER...13706
HANDLING AUTO-GREASING SYSTEM...13734
METHOD OF OPERATING AUTO-GREASING SYSTEM...13734
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM...13741
TROUBLESHOOTING...13741
HANDLING QUICK COUPLER CONTROL SYSTEM...13742
EXPLANATION OF COMPONENTS...13742
FUNCTION AND METHOD OF OPERATION OF QUICK COUPLER SWITCH...13745
METHOD OF REMOVING AND INSTALLING ATTACHMENT...13747
INSPECTION AND MAINTENANCE...13752
METHOD OF TURNING BOTTOM FRONT WORKING LAMP ON/OFF...13753
HANDLING BATTERY DISCONNECTOR SWITCH...13754
EXPLANATION OF COMPONENTS...13754
HANDLING...13754
HANDLING STARTING AID CONNECTOR...13756
HANDLING REAR FENDER...13758
HANDLING...13758
METHOD OF USING 3 LEVERS...13759
EXPLANATION OF COMPONENTS...13759
HANDLING MACHINES EQUIPPED WITH VHMS...13761
VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED...13761
VHMS AND COMMUNICATIONS TERMINAL INSTALLED...13761
INDEX...13763
TEN00296-02 - Wheel Loader WA600-6 Operation & Maintenance Manual...13767
COVER...13767
FOREWORD...13768
BEFORE READING THIS MANUAL...13769
SAFETY INFORMATION...13770
INTRODUCTION...13771
USE OF MACHINE...13771
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...13771
VISIBILITY FROM OPERATOR'S SEAT...13772
NECESSARY INFORMATION...13773
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...13773
EPA REGULATIONS, ENGINE NUMBER PLATE...13773
POSITION OF SERVICE METER...13774
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...13774
CONTENTS...13775
SAFETY...13780
SAFETY...13781
SAFETY LABELS...13784
LOCATION OF SAFETY LABELS...13785
SAFETY LABELS...13786
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...13793
PRECAUTIONS BEFORE STARTING OPERATION...13793
PREPARATIONS FOR SAFE OPERATION...13793
FIRE PREVENTION...13795
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE...13796
DO NOT GET CAUGHT IN ARTICULATING PORTION...13799
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...13799
UNAUTHORIZED MODIFICATION...13799
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...13800
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING...13800
PRECAUTIONS FOR OPERATION...13801
PRECAUTIONS FOR JOBSITE...13801
STARTING ENGINE...13803
OPERATION...13806
TRANSPORTATION...13813
TOWING...13814
PRECAUTIONS FOR MAINTENANCE...13815
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE...13815
PRECAUTIONS FOR INSPECTION AND MAINTENANCE...13820
TIRES...13825
OPERATION...13828
GENERAL VIEW...13829
GENERAL VIEW OF MACHINE...13829
GENERAL VIEW OF CONTROLS AND GAUGES...13830
EXPLANATION OF COMPONENTS...13836
MACHINE MONITOR...13836
SWITCHES...13877
CONTROL LEVERS, PEDALS...13902
CAP WITH LOCK...13909
FRAME LOCK BAR...13911
TOWING PIN...13912
BACKUP ALARM...13912
OPENING, CLOSING CAB DOORS, WINDOWS...13913
HANDLING CAB WIPER...13916
DUST INDICATOR...13917
FUSE...13918
CIRCUIT BREAKER...13920
SLOW BLOW FUSE...13921
LUNCH BOX TRAY...13921
TOOL BOX...13921
GREASE PUMP...13921
LOCATION OF FIRE EXTINGUISHER...13922
POWER OUTLET...13922
AM/FM RADIO-CASSETTE STEREO...13923
AIR CONDITIONER...13932
OPERATION...13947
CHECK BEFORE STARTING ENGINE, ADJUST...13947
STARTING ENGINE...13966
OPERATIONS AND CHECKS AFTER STARTING ENGINE...13968
STOPPING ENGINE...13971
CHECK AFTER STOPPING ENGINE...13971
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...13972
TURNING...13980
OPERATION OF WORK EQUIPMENT...13982
SEMI AUTO DIGGING OPERATIONS...13984
REMOTE POSITIONER...13985
WORK POSSIBLE USING WHEEL LOADER...13987
PRECAUTIONS FOR OPERATION...14007
REMOVAL AND INSTALLATION OF THE BUCKET...14010
PARKING MACHINE...14014
CHECKS AFTER COMPLETION OF OPERATION...14016
LOCKING...14016
HANDLING THE TIRES...14017
TRANSPORTATION...14020
TRANSPORTATION PROCEDURE...14020
LOADING, UNLOADING WORK...14020
METHOD OF SECURING MACHINE...14020
METHOD OF LIFTING MACHINE...14022
PRECAUTIONS WHEN DISASSEMBLY OR REASSEMBLING WORK EQUIPMENT...14025
COLD WEATHER OPERATION...14026
PRECAUTIONS FOR LOW TEMPERATURE...14026
PRECAUTIONS AFTER COMPLETION OF WORK...14027
AFTER COLD WEATHER...14027
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...14028
LONG-TERM STORAGE...14029
BEFORE STORAGE...14029
DURING STORAGE...14029
AFTER STORAGE...14029
TROUBLESHOOTING...14030
WHEN MACHINE RUNS OUT OF FUEL...14030
METHOD OF TOWING MACHINE...14030
IF BATTERY IS DISCHARGED...14035
METHOD FOR LOWERING WORK EQUIPMENT WHEN ENGINE HAS STOPPED...14039
OTHER TROUBLE...14040
MAINTENANCE...14044
GUIDES TO MAINTENANCE...14045
OUTLINES OF SERVICE...14047
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...14047
OUTLINE OF ELECTRIC SYSTEM...14051
WEAR PARTS...14052
WEAR PARTS LIST...14053
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...14054
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...14055
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...14057
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...14058
TORQUE LIST...14058
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...14060
SAFETY CRITICAL PARTS...14061
MAINTENANCE SCHEDULE CHART...14063
MAINTENANCE SCHEDULE CHART...14063
SERVICE PROCEDURE...14065
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)...14065
INITIAL 250 HOURS SERVICE...14065
WHEN REQUIRED...14066
CHECK BEFORE STARTING...14096
EVERY 50 HOURS SERVICE...14097
EVERY 100 HOURS SERVICE...14098
EVERY 250 HOURS SERVICE...14103
EVERY 500 HOURS SERVICE...14106
EVERY 1000 HOURS SERVICE...14114
EVERY 2000 HOURS SERVICE...14119
EVERY 4000 HOURS SERVICE...14127
EVERY 8000 HOURS SERVICE...14132
SPECIFICATIONS...14134
SPECIFICATIONS...14135
ATTACHMENTS, OPTIONS...14140
HANDLING STEERING WHEEL SPECIFICATION MACHINE...14141
EXPLANATION OF COMPONENTS...14141
FUNCTIONS OF STEERING WHEEL SPECIFICATION MACHINE...14151
SELECTING BUCKET AND TIRES...14161
STARTING IN COLD AREAS...14162
ELECTRIC HEATER...14162
HANDLING LOAD METER...14166
OUTLINE OF LOAD METER...14166
PRINCIPLE OF LOAD METER MEASUREMENT...14168
POINTS TO REMEMBER TO ENSURE HIGH ACCURACY...14169
USING LOAD METER...14171
HANDLING AUTO-GREASING SYSTEM...14199
METHOD OF OPERATING AUTO-GREASING SYSTEM...14199
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM...14206
TROUBLESHOOTING...14206
HANDLING QUICK COUPLER CONTROL SYSTEM...14207
EXPLANATION OF COMPONENTS...14207
FUNCTION AND METHOD OF OPERATION OF QUICK COUPLER SWITCH...14210
METHOD OF REMOVING AND INSTALLING ATTACHMENT...14212
INSPECTION AND MAINTENANCE...14217
METHOD OF TURNING BOTTOM FRONT WORKING LAMP ON/OFF...14218
HANDLING BATTERY DISCONNECTOR SWITCH...14219
EXPLANATION OF COMPONENTS...14219
HANDLING...14219
HANDLING STARTING AID CONNECTOR...14221
HANDLING REAR FENDER...14223
HANDLING...14223
METHOD OF USING 3 LEVERS...14224
EXPLANATION OF COMPONENTS...14224
HANDLING MACHINES EQUIPPED WITH VHMS...14226
VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED...14226
VHMS AND COMMUNICATIONS TERMINAL INSTALLED...14226
INDEX...14228
TEN00372-01 - Wheel Loader WA600-6 Operation & Maintenance Manual...14232
COVER...14232
FOREWORD...14233
BEFORE READING THIS MANUAL...14234
SAFETY INFORMATION...14235
INTRODUCTION...14236
USE OF MACHINE...14236
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...14236
VISIBILITY FROM OPERATOR'S SEAT...14237
NECESSARY INFORMATION...14238
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...14238
EPA REGULATIONS, ENGINE NUMBER PLATE...14238
POSITION OF SERVICE METER...14239
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...14239
CONTENTS...14240
SAFETY...14245
SAFETY...14246
SAFETY LABELS...14249
LOCATION OF SAFETY LABELS...14250
SAFETY LABELS...14251
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...14258
PRECAUTIONS BEFORE STARTING OPERATION...14258
PREPARATIONS FOR SAFE OPERATION...14258
FIRE PREVENTION...14260
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE...14261
DO NOT GET CAUGHT IN ARTICULATING PORTION...14264
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...14264
UNAUTHORIZED MODIFICATION...14264
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...14265
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING...14265
PRECAUTIONS FOR OPERATION...14266
PRECAUTIONS FOR JOBSITE...14266
STARTING ENGINE...14268
OPERATION...14271
TRANSPORTATION...14278
TOWING...14279
PRECAUTIONS FOR MAINTENANCE...14280
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE...14280
PRECAUTIONS FOR INSPECTION AND MAINTENANCE...14285
TIRES...14290
OPERATION...14293
GENERAL VIEW...14294
GENERAL VIEW OF MACHINE...14294
GENERAL VIEW OF CONTROLS AND GAUGES...14295
EXPLANATION OF COMPONENTS...14301
MACHINE MONITOR...14301
SWITCHES...14342
CONTROL LEVERS, PEDALS...14367
CAP WITH LOCK...14374
FRAME LOCK BAR...14376
TOWING PIN...14377
BACKUP ALARM...14377
OPENING, CLOSING CAB DOORS, WINDOWS...14378
HANDLING CAB WIPER...14381
DUST INDICATOR...14382
FUSE...14383
CIRCUIT BREAKER...14385
SLOW BLOW FUSE...14386
LUNCH BOX TRAY...14386
TOOL BOX...14386
GREASE PUMP...14386
LOCATION OF FIRE EXTINGUISHER...14387
POWER OUTLET...14387
AM/FM RADIO-CASSETTE STEREO...14388
AIR CONDITIONER...14397
OPERATION...14412
CHECK BEFORE STARTING ENGINE, ADJUST...14412
STARTING ENGINE...14431
OPERATIONS AND CHECKS AFTER STARTING ENGINE...14433
STOPPING ENGINE...14436
CHECK AFTER STOPPING ENGINE...14436
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...14437
TURNING...14445
OPERATION OF WORK EQUIPMENT...14447
SEMI AUTO DIGGING OPERATIONS...14449
REMOTE POSITIONER...14450
WORK POSSIBLE USING WHEEL LOADER...14452
PRECAUTIONS FOR OPERATION...14472
REMOVAL AND INSTALLATION OF THE BUCKET...14475
PARKING MACHINE...14479
CHECKS AFTER COMPLETION OF OPERATION...14481
LOCKING...14481
HANDLING THE TIRES...14482
TRANSPORTATION...14485
TRANSPORTATION PROCEDURE...14485
LOADING, UNLOADING WORK...14485
METHOD OF SECURING MACHINE...14485
METHOD OF LIFTING MACHINE...14487
PRECAUTIONS WHEN DISASSEMBLY OR REASSEMBLING WORK EQUIPMENT...14490
COLD WEATHER OPERATION...14491
PRECAUTIONS FOR LOW TEMPERATURE...14491
PRECAUTIONS AFTER COMPLETION OF WORK...14492
AFTER COLD WEATHER...14492
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...14493
LONG-TERM STORAGE...14494
BEFORE STORAGE...14494
DURING STORAGE...14494
AFTER STORAGE...14494
TROUBLESHOOTING...14495
WHEN MACHINE RUNS OUT OF FUEL...14495
METHOD OF TOWING MACHINE...14495
IF BATTERY IS DISCHARGED...14500
METHOD FOR LOWERING WORK EQUIPMENT WHEN ENGINE HAS STOPPED...14504
OTHER TROUBLE...14505
MAINTENANCE...14509
GUIDES TO MAINTENANCE...14510
OUTLINES OF SERVICE...14512
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...14512
OUTLINE OF ELECTRIC SYSTEM...14516
WEAR PARTS...14517
WEAR PARTS LIST...14518
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...14519
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...14520
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...14522
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...14523
TORQUE LIST...14523
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...14525
SAFETY CRITICAL PARTS...14526
MAINTENANCE SCHEDULE CHART...14528
MAINTENANCE SCHEDULE CHART...14528
SERVICE PROCEDURE...14530
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)...14530
INITIAL 250 HOURS SERVICE...14530
WHEN REQUIRED...14531
CHECK BEFORE STARTING...14560
EVERY 50 HOURS SERVICE...14561
EVERY 100 HOURS SERVICE...14562
EVERY 250 HOURS SERVICE...14567
EVERY 500 HOURS SERVICE...14570
EVERY 1000 HOURS SERVICE...14578
EVERY 2000 HOURS SERVICE...14583
EVERY 4000 HOURS SERVICE...14591
EVERY 8000 HOURS SERVICE...14596
SPECIFICATIONS...14597
SPECIFICATIONS...14598
ATTACHMENTS, OPTIONS...14603
HANDLING STEERING WHEEL SPECIFICATION MACHINE...14604
EXPLANATION OF COMPONENTS...14604
FUNCTIONS OF STEERING WHEEL SPECIFICATION MACHINE...14614
SELECTING BUCKET AND TIRES...14624
STARTING IN COLD AREAS...14625
ELECTRIC HEATER...14625
HANDLING LOAD METER...14630
OUTLINE OF LOAD METER...14630
PRINCIPLE OF LOAD METER MEASUREMENT...14632
POINTS TO REMEMBER TO ENSURE HIGH ACCURACY...14633
USING LOAD METER...14635
HANDLING AUTO-GREASING SYSTEM...14663
METHOD OF OPERATING AUTO-GREASING SYSTEM...14663
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM...14670
TROUBLESHOOTING...14670
HANDLING QUICK COUPLER CONTROL SYSTEM...14671
EXPLANATION OF COMPONENTS...14671
FUNCTION AND METHOD OF OPERATION OF QUICK COUPLER SWITCH...14674
METHOD OF REMOVING AND INSTALLING ATTACHMENT...14676
INSPECTION AND MAINTENANCE...14681
METHOD OF TURNING BOTTOM FRONT WORKING LAMP ON/OFF...14682
HANDLING BATTERY DISCONNECTOR SWITCH...14683
EXPLANATION OF COMPONENTS...14683
HANDLING...14683
HANDLING STARTING AID CONNECTOR...14685
HANDLING REAR FENDER...14687
HANDLING...14687
METHOD OF USING 3 LEVERS...14688
EXPLANATION OF COMPONENTS...14688
HANDLING MACHINES EQUIPPED WITH VHMS...14690
VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED...14690
VHMS AND COMMUNICATIONS TERMINAL INSTALLED...14691
INDEX...14693
TEN00462-02 - Wheel Loader WA600-6 Operation & Maintenance Manual...14697
COVER...14697
FOREWORD...14698
BEFORE READING THIS MANUAL...14699
SAFETY INFORMATION...14700
INTRODUCTION...14701
USE OF MACHINE...14701
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...14701
VISIBILITY FROM OPERATOR'S SEAT...14702
NECESSARY INFORMATION...14703
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...14703
EPA REGULATIONS, ENGINE NUMBER PLATE...14703
POSITION OF SERVICE METER...14704
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...14704
CONTENTS...14705
SAFETY...14710
SAFETY...14711
SAFETY LABELS...14714
LOCATION OF SAFETY LABELS...14715
SAFETY LABELS...14716
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...14723
PRECAUTIONS BEFORE STARTING OPERATION...14723
PREPARATIONS FOR SAFE OPERATION...14723
FIRE PREVENTION...14725
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE...14726
DO NOT GET CAUGHT IN ARTICULATING PORTION...14729
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...14729
UNAUTHORIZED MODIFICATION...14729
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...14730
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING...14730
PRECAUTIONS FOR OPERATION...14731
PRECAUTIONS FOR JOBSITE...14731
STARTING ENGINE...14733
OPERATION...14736
TRANSPORTATION...14743
TOWING...14744
PRECAUTIONS FOR MAINTENANCE...14745
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE...14745
PRECAUTIONS FOR INSPECTION AND MAINTENANCE...14750
TIRES...14755
OPERATION...14758
GENERAL VIEW...14759
GENERAL VIEW OF MACHINE...14759
GENERAL VIEW OF CONTROLS AND GAUGES...14760
EXPLANATION OF COMPONENTS...14766
MACHINE MONITOR...14766
SWITCHES...14807
CONTROL LEVERS, PEDALS...14832
CAP WITH LOCK...14839
FRAME LOCK BAR...14841
TOWING PIN...14842
BACKUP ALARM...14842
OPENING, CLOSING CAB DOORS, WINDOWS...14843
HANDLING CAB WIPER...14846
DUST INDICATOR...14847
FUSE...14848
CIRCUIT BREAKER...14850
SLOW BLOW FUSE...14851
LUNCH BOX TRAY...14851
TOOL BOX...14851
GREASE PUMP...14851
LOCATION OF FIRE EXTINGUISHER...14852
POWER OUTLET...14852
AM/FM RADIO-CASSETTE STEREO...14853
AIR CONDITIONER...14862
OPERATION...14877
CHECK BEFORE STARTING ENGINE, ADJUST...14877
STARTING ENGINE...14896
OPERATIONS AND CHECKS AFTER STARTING ENGINE...14898
STOPPING ENGINE...14901
CHECK AFTER STOPPING ENGINE...14901
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...14902
TURNING...14910
OPERATION OF WORK EQUIPMENT...14912
SEMI AUTO DIGGING OPERATIONS...14914
REMOTE POSITIONER...14915
WORK POSSIBLE USING WHEEL LOADER...14917
PRECAUTIONS FOR OPERATION...14937
REMOVAL AND INSTALLATION OF THE BUCKET...14940
PARKING MACHINE...14944
CHECKS AFTER COMPLETION OF OPERATION...14946
名称未設定...14946
HANDLING THE TIRES...14947
TRANSPORTATION...14950
TRANSPORTATION PROCEDURE...14950
LOADING, UNLOADING WORK...14950
METHOD OF SECURING MACHINE...14950
METHOD OF LIFTING MACHINE...14952
PRECAUTIONS WHEN DISASSEMBLY OR REASSEMBLING WORK EQUIPMENT...14955
COLD WEATHER OPERATION...14956
PRECAUTIONS FOR LOW TEMPERATURE...14956
PRECAUTIONS AFTER COMPLETION OF WORK...14957
AFTER COLD WEATHER...14957
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...14958
LONG-TERM STORAGE...14959
BEFORE STORAGE...14959
DURING STORAGE...14959
AFTER STORAGE...14959
TROUBLESHOOTING...14960
WHEN MACHINE RUNS OUT OF FUEL...14960
METHOD OF TOWING MACHINE...14960
IF BATTERY IS DISCHARGED...14965
METHOD FOR LOWERING WORK EQUIPMENT WHEN ENGINE HAS STOPPED...14969
OTHER TROUBLE...14970
MAINTENANCE...14974
GUIDES TO MAINTENANCE...14975
OUTLINES OF SERVICE...14977
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...14977
OUTLINE OF ELECTRIC SYSTEM...14981
WEAR PARTS...14982
WEAR PARTS LIST...14983
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...14984
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...14985
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...14987
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...14988
TORQUE LIST...14988
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...14990
SAFETY CRITICAL PARTS...14991
MAINTENANCE SCHEDULE CHART...14993
MAINTENANCE SCHEDULE CHART...14993
SERVICE PROCEDURE...14995
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)...14995
INITIAL 250 HOURS SERVICE...14995
WHEN REQUIRED...14996
CHECK BEFORE STARTING...15025
EVERY 50 HOURS SERVICE...15026
EVERY 100 HOURS SERVICE...15027
EVERY 250 HOURS SERVICE...15032
EVERY 500 HOURS SERVICE...15035
EVERY 1000 HOURS SERVICE...15043
EVERY 2000 HOURS SERVICE...15048
EVERY 4000 HOURS SERVICE...15056
EVERY 8000 HOURS SERVICE...15061
SPECIFICATIONS...15062
SPECIFICATIONS...15063
ATTACHMENTS, OPTIONS...15068
HANDLING STEERING WHEEL SPECIFICATION MACHINE...15069
EXPLANATION OF COMPONENTS...15069
FUNCTIONS OF STEERING WHEEL SPECIFICATION MACHINE...15079
SELECTING BUCKET AND TIRES...15089
STARTING IN COLD AREAS...15090
ELECTRIC HEATER...15090
HANDLING LOAD METER...15095
OUTLINE OF LOAD METER...15095
PRINCIPLE OF LOAD METER MEASUREMENT...15097
POINTS TO REMEMBER TO ENSURE HIGH ACCURACY...15098
USING LOAD METER...15100
HANDLING AUTO-GREASING SYSTEM...15128
METHOD OF OPERATING AUTO-GREASING SYSTEM...15128
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM...15135
TROUBLESHOOTING...15135
HANDLING QUICK COUPLER CONTROL SYSTEM...15136
EXPLANATION OF COMPONENTS...15136
FUNCTION AND METHOD OF OPERATION OF QUICK COUPLER SWITCH...15139
METHOD OF REMOVING AND INSTALLING ATTACHMENT...15141
INSPECTION AND MAINTENANCE...15146
METHOD OF TURNING BOTTOM FRONT WORKING LAMP ON/OFF...15147
HANDLING BATTERY DISCONNECTOR SWITCH...15148
EXPLANATION OF COMPONENTS...15148
HANDLING...15148
HANDLING STARTING AID CONNECTOR...15150
HANDLING REAR FENDER...15152
HANDLING...15152
METHOD OF USING 3 LEVERS...15153
EXPLANATION OF COMPONENTS...15153
HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus...15155
KOMTRAX Plus INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED...15155
KOMTRAX Plus AND COMMUNICATIONS TERMINAL INSTALLED...15155
INDEX...15158
Komatsu Wheel Loader WA600 Repair Service Manual
