Komatsu WHEEL LOADER WA475, WA475-E0 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu WHEEL LOADER WA475-10, WA475-10E0, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu WHEEL LOADER WA475-10, WA475-10EO 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.
SEN06773-04 - Komatsu WHEEL LOADER WA475-10, WA475-10E0 (SERIAL NUMBERS 120001 and up) Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 4,353 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
COVER...1
00 INDEX AND FOREWORD...1
INDEX...2
FOREWORD, SAFETY, BASIC INFORMATION...27
HOW TO READ THE SHOP MANUAL...27
SAFETY NOTICE FOR OPERATION...29
PRECAUTIONS TO PREVENT FIRE...37
ACTIONS IF FIRE OCCURS...39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS...40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...41
PRECAUTIONS FOR DEF...42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING...42
PRECAUTIONS FOR ADDING...42
PRECAUTIONS FOR STORING...42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE...42
THE OTHER PRECAUTIONS...42
STORE AdBlue/DEF...43
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT...44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS...47
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT...54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT...56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT...57
PRACTICAL USE OF KOMTRAX...58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER...59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER...59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER...60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER...61
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR...67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR...68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL...70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH...71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE...73
HOW TO READ ELECTRICAL WIRE CODE...74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...78
STANDARD TIGHTENING TORQUE TABLE...81
CONVERSION TABLE...88
ABBREVIATION LIST...93
01 SPECIFICATIONS...1
CONTENTS...2
SPECIFICATIONS...3
SPECIFICATION DRAWING...3
SPECIFICATION DRAWING: WA475-10...3
SPECIFICATION DRAWING: WA475-10E0...5
SPECIFICATIONS...7
SPECIFICATIONS: WA475-10...7
SPECIFICATIONS: WA475-10E0...12
WEIGHT TABLE...17
WEIGHT TABLE: WA475-10...17
WEIGHT TABLE: WA475-10E0...19
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA)...21
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...21
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION)...23
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...23
10 STRUCTURE AND FUNCTION...1
CONTENTS...2
UREA SCR SYSTEM...7
LAYOUT DRAWING OF UREA SCR SYSTEM...7
UREA SCR SYSTEM DIAGRAM...9
FUNCTION OF UREA SCR SYSTEM...10
FUNCTION OF AdBlue/DEF SYSTEM...10
INDUCEMENT STRATEGY...12
COMPONENT PARTS OF UREA SCR SYSTEM...26
AdBlue/DEF MIXING TUBE...26
SCR ASSEMBLY...27
AdBlue/DEF TANK...29
AdBlue/DEF PUMP...31
AdBlue/DEF INJECTOR...32
AdBlue/DEF HOSE...33
AdBlue/DEF TANK HEATING VALVE...34
BOOT-UP SYSTEM...35
LAYOUT DRAWING OF BOOT-UP SYSTEM...35
SYSTEM OPERATING LAMP SYSTEM...37
SYSTEM DIAGRAM OF SYSTEM OPERATING LAMP SYSTEM...37
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM...37
BATTERY DISCONNECT SWITCH...39
FUNCTION OF BATTERY DISCONNECT SWITCH...39
OPERATION OF BATTERY DISCONNECT SWITCH...39
PREHEATING SYSTEM...40
PREHEATING SYSTEM DIAGRAM...40
FUNCTION OF AUTOMATIC PREHEATING SYSTEM...40
OPERATION OF AUTOMATIC PREHEATING SYSTEM...40
FUNCTION OF MANUAL PREHEATING SYSTEM...41
OPERATION OF MANUAL PREHEATING SYSTEM...41
ENGINE SYSTEM...42
LAYOUT DRAWING OF ENGINE SYSTEM...42
FUNCTION OF ENGINE SYSTEM...43
ENGINE CONTROL SYSTEM...44
SYSTEM DIAGRAM OF ENGINE CONTROL...44
FUNCTION OF ENGINE CONTROL SYSTEM...45
OPERATION OF ENGINE CONTROL SYSTEM...46
AUTOMATIC IDLE STOP SYSTEM...48
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM...48
COMPONENT PARTS OF ENGINE SYSTEM...49
VGT...49
EGR SYSTEM...53
EGR VALVE...55
EGR COOLER...57
KCCV SYSTEM...58
KCCV VENTILATOR...60
KDPF...62
COOLING SYSTEM...66
LAYOUT DRAWING OF COOLING SYSTEM...66
SPECIFICATIONS OF COOLING SYSTEM...67
COOLING FAN CONTROL SYSTEM...68
SYSTEM DIAGRAM OF COOLING FAN CONTROL SYSTEM...68
FUNCTION OF COOLING FAN CONTROL SYSTEM...69
COMPONENT PARTS OF COOLING SYSTEM...73
BRAKE AND COOLING FAN PUMP...73
COOLING FAN MOTOR...81
CONTROL SYSTEM...88
LAYOUT DRAWING OF CONTROL SYSTEM PARTS...88
MACHINE MONITOR SYSTEM...90
SYSTEM DIAGRAM OF MACHINE MONITOR SYSTEM...90
FUNCTION OF MACHINE MONITOR SYSTEM...90
REARVIEW MONITOR SYSTEM...92
SYSTEM DIAGRAM OF REARVIEW MONITOR SYSTEM...92
FUNCTION OF REARVIEW MONITOR SYSTEM...92
KOMTRAX SYSTEM...93
SYSTEM DIAGRAM OF KOMTRAX SYSTEM...93
FUNCTION OF KOMTRAX SYSTEM...93
LOAD METER SYSTEM...94
SYSTEM DIAGRAM OF LOAD METER...94
FUNCTION OF LOAD METER SYSTEM...94
COMPONENT PARTS OF CONTROL SYSTEM...99
MACHINE MONITOR...99
MONITOR SWITCH...119
KEYPAD...120
REARVIEW MONITOR...121
REARVIEW CAMERA...123
Gateway Controller...124
COMMUNICATION TERMINAL...127
TRANSMISSION CONTROLLER...128
WORK EQUIPMENT CONTROLLER...132
MONITOR CONTROLLER...136
CAN TERMINATING RESISTOR...141
ENGINE CONTROLLER...142
ACCELERATOR PEDAL...149
SPEED CONTROL DIAL...151
HYDRAULIC SYSTEM...152
LAYOUT DRAWING OF HYDRAULIC SYSTEM...152
CLSS...153
STRUCTURE OF CLSS...153
FUNCTION OF CLSS...154
WORK EQUIPMENT PUMP AND STEERING PUMP CONTROL SYSTEM...157
SWASH PLATE CONTROL FUNCTION OF WORK EQUIPMENT PUMP AND STEERING PUMP...157
PICKUP ASSISTANCE CONTROL FUNCTION WHEN ENGINE SPEED IS LOW...157
OVERHEAT PREVENTION FUNCTION OF WORK EQUIPMENT CIRCUIT...157
COMPONENT PARTS OF HYDRAULIC SYSTEM...158
HYDRAULIC TANK...158
WORK EQUIPMENT PUMP...161
STEERING PUMP...179
POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP...192
CONTROL VALVE...193
TOTAL CONTROL SYSTEM...233
SYSTEM DIAGRAM OF TOTAL CONTROL SYSTEM...233
INDEPENDENT WORK EQUIPMENT CONTROL FUNCTION...234
POWER MODE SELECTOR FUNCTION...236
OVERHEAT PREVENTION FUNCTION...237
OUTPUT LIMITATION FUNCTION FOR LOW TEMPERATURE...238
WORK EQUIPMENT SPEED LEVEL...239
POWER TRAIN SYSTEM...240
LAYOUT DRAWING OF POWER TRAIN SYSTEM...240
OPERATION OF POWER TRAIN SYSTEM...242
HST CHARGE SYSTEM...243
SYSTEM DIAGRAM OF HST CHARGE SYSTEM...243
FUNCTION OF HST CHARGE SYSTEM...243
PUMP MOTOR CONTROL SYSTEM...244
SYSTEM DIAGRAM OF PUMP MOTOR CONTROL SYSTEM...244
STEPLESS GEAR SHIFT ADJUSTMENT FUNCTION...244
INCHING CONTROL FUNCTION...245
TRANSMISSION GEAR SHIFT CONTROL SYSTEM...246
SYSTEM DIAGRAM OF TRANSMISSION GEAR SHIFT CONTROL SYSTEM...246
AUTOMATIC GEAR SHIFT FUNCTION...246
GEAR SHIFT DISPLAY FUNCTION...247
HUNTING PREVENTION FUNCTION...247
TRANSMISSION PROTECTION FUNCTION...248
SPEED LIMITATION FUNCTION...248
NEUTRALIZER FUNCTION...248
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION...249
TRACTION CONTROL SYSTEM...251
SYSTEM DIAGRAM OF TRACTION CONTROL SYSTEM...251
FUNCTION OF TRACTION CONTROL SYSTEM...251
COMPONENT PARTS OF POWER TRAIN SYSTEM...254
DRIVE SHAFT...254
TRANSMISSION...256
TRANSMISSION CONTROL VALVE...258
ECMV...260
VALVE ASSEMBLY (MAIN RELIEF, POWER TRAIN OIL COOLER RELIEF)...262
SOLENOID VALVE (TRANSMISSION CHARGE PUMP BYPASS)...265
HST PUMP MOTOR...267
HST VALVE...274
HST CHARGE PUMP...280
PILOT SEQUENSE VALVE...281
MANIFOLD VALVE...284
SOLENOID VALVE (HST CHARGE PUMP BYPASS)...287
AXLE...289
CONVENTIONAL DIFFERENTIAL...291
LIMITED SLIP DIFFERENTIAL...294
FINAL DRIVE...299
AJSS KNOB...301
COMBINATION SWITCH...302
WORK EQUIPMENT SYSTEM...306
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM...306
WORK EQUIPMENT CONTROL SYSTEM...308
WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE...308
WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION...308
WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM...309
WORK EQUIPMENT LEVER OPERATION FUNCTION...310
BOOM STOP MODULATION FUNCTION...310
WORK EQUIPMENT SHOCK REDUCTION FUNCTION...311
WORK EQUIPMENT NEUTRAL LOCK SYSTEM...314
WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM...314
FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM...314
REMOTE POSITIONER SYSTEM...316
REMOTE BUCKET POSITIONER SYSTEM DIAGRAM...316
FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM...316
REMOTE BOOM POSITIONER SYSTEM DIAGRAM...318
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM...318
AUTOMATIC BUCKET SHAKE SYSTEM...321
SYSTEM DIAGRAM OF AUTOMATIC BUCKET SHAKE SYSTEM...321
FUNCTION OF AUTOMATIC BUCKET SHAKE SYSTEM...321
BUCKET POSITIONER AND BOOM POSITIONER...322
STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER...322
AUTO-DIGGING SYSTEM...323
AUTO-DIGGING SYSTEM DIAGRAM...323
FUNCTION OF AUTO-DIGGING SYSTEM...324
ECSS...326
ECSS DIAGRAM...326
FUNCTION OF ECSS...326
OPERATION OF ECSS...326
WORK EQUIPMENT SYSTEM...328
WORK EQUIPMENT LOCK SOLENOID VALVE...328
PILOT CIRCUIT ACCUMULATOR...329
ECSS CIRCUIT ACCUMULATOR...330
WORK EQUIPMENT ELECTRIC LEVER...332
BUCKET CONTROL SWITCH...335
MULTIFUNCTION MONO-LEVER...336
STEERING SYSTEM...338
LAYOUT DRAWING OF STEERING SYSTEM...338
SECONDARY STEERING SYSTEM...341
SECONDARY STEERING SYSTEM DIAGRAM...341
FUNCTION OF SECONDARY STEERING SYSTEM...341
AJSS...343
LAYOUT DRAWING OF AJSS...343
AJSS SYSTEM DIAGRAM...344
FUNCTION OF AJSS...345
NEUTRALIZER FUNCTION OF AJSS...345
NEUTRAL INTERLOCK FUNCTION OF AJSS...346
SPEED SENSING STEERING FUNCTION OF AJSS...347
TURN SIGNAL PILOT LAMP CONTROL FUNCTION OF AJSS...348
STEERING COLUMN...349
STRUCTURE OF STEERING COLUMN...349
STEERING SYSTEM...350
AJSS EPC VALVE...350
STEERING LOCK VALVE...351
ROTARY VALVE...352
ORBITROL VALVE...355
STOP VALVE...359
STEERING VALVE...360
SECONDARY STEERING PUMP...372
SECONDARY STEERING MOTOR...373
BRAKE SYSTEM...374
LAYOUT DRAWING OF BRAKE SYSTEM...374
LAYOUT DRAWING OF BRAKE COOLING SYSTEM...376
PARKING BRAKE CONTROL SYSTEM...378
PARKING BRAKE CONTROL SYSTEM DIAGRAM...378
OPERATION OF PARKING BRAKE CONTROL SYSTEM...378
BRAKE COOLING CONTROL SYSTEM...380
BRAKE COOLING CONTROL SYSTEM DIAGRAM...380
FUNCTION OF BRAKE COOLING CONTROL SYSTEM...380
COMPONENT PARTS OF BRAKE SYSTEM...381
CHARGE VALVE...381
PARKING BRAKE SOLENOID VALVE...386
PARKING BRAKE EMERGENCY RELEASE VALVE...388
BRAKE CIRCUIT ACCUMULATOR...389
BRAKE VALVE...391
SLACK ADJUSTER...395
BRAKE...397
PARKING BRAKE...400
BRAKE COOLING PUMP...402
BRAKE COOLING OIL COOLER...403
AUTO-GREASING SYSTEM...404
LAYOUT DRAWING OF AUTOMATIC GREASE SYSTEM...404
SPECIFICATIONS OF AUTOMATIC GREASE SYSTEM...405
FUNCTION OF AUTO-GREASING SYSTEM...407
COMPONENT PARTS OF AUTO-GREASING SYSTEM...408
AUTO-GREASING PUMP...408
UNDERCARRIAGE AND FRAME...409
FRAME, AXLE MOUNT AND CENTER HINGE PIN...409
STRUCTURE OF FRAME, AXLE MOUNT, CENTER HINGE PIN...409
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN...409
TIRE...411
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE...411
STRUCTURE OF RADIAL TIRE...411
FUNCTION OF RADIAL TIRE...412
STRUCTURE OF BIAS TIRE...412
FUNCTION OF BIAS TIRE...412
WORK EQUIPMENT...413
STRUCTURE OF WORK EQUIPMENT...413
STRUCTURE OF BUCKET...414
CAB AND ITS ATTACHMENTS...415
ROPS CAB...415
STRUCTURE OF ROPS CAB...415
FUNCTION OF ROPS CAB...415
!!! new_index = 539
!!! num_start = 1
!!! num_style = Arabic
20 STANDARD VALUE TABLE...1
CONTENTS...2
STANDARD VALUE TABLE FOR ENGINE...3
STANDARD VALUE TABLE FOR ENGINE: WA475-10...3
STANDARD VALUE TABLE FOR ENGINE: WA475-10E0...7
STANDARD VALUE TABLE FOR MACHINE...11
STANDARD VALUE TABLE FOR MACHINE: WA475-10...11
STANDARD VALUE TABLE FOR MACHINE: WA475-10E0...34
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE...56
30 TESTING AND ADJUSTING...1
CONTENTS...2
RELATED INFORMATION ON TESTING AND ADJUSTING...6
TOOLS FOR TESTING AND ADJUSTING...6
SKETCH OF TOOLS FOR TESTING AND ADJUSTING...16
ENGINE AND COOLING SYSTEM...18
TEST ENGINE SPEED...18
TEST ENGINE SPEED...18
TEST BOOST PRESSURE...20
TEST BOOST PRESSURE ON MACHINE MONITOR...20
TEST BOOST PRESSURE BY TESTING TOOL...21
TEST EXHAUST GAS TEMPERATURE...24
TEST EXHAUST GAS TEMPERATURE...25
TEST EXHAUST GAS COLOR...27
TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER...27
TEST EXHAUST GAS COLOR BY SMOKE METER...29
CHECK AND ADJUST VALVE CLEARANCE...31
TEST VALVE CLEARANCE...31
ADJUST VALVE CLEARANCE...33
TEST COMPRESSION PRESSURE...34
TEST COMPRESSION PRESSURE...34
TEST BLOWBY PRESSURE...37
TEST BLOWBY PRESSURE...37
TEST ENGINE OIL PRESSURE...40
TEST ENGINE OIL PRESSURE ON MACHINE MONITOR...40
TEST ENGINE OIL PRESSURE BY TESTING TOOL...40
TEST EGR VALVE AND VGT OIL PRESSURE...43
TEST EGR VALVE AND VGT OIL PRESSURE...43
TEST FUEL PRESSURE...45
TEST FUEL PRESSURE...45
TEST FUEL RETURN RATE AND LEAKAGE...48
TEST FUEL RETURN RATE AND LEAKAGE...49
BLEED AIR FROM FUEL SYSTEM...53
BLEED AIR FROM FUEL SYSTEM...54
TEST FUEL CIRCUIT FOR LEAKAGE...56
TEST FUEL CIRCUIT FOR LEAKAGE...56
CYLINDER CUT-OUT MODE OPERATION...59
NO-INJECTION CRANKING OPERATION...60
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE...61
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE...61
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS...62
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS...62
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS...63
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS...63
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION...64
TEST AIR CONDITIONER COMPRESSOR BELT TENSION...64
ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION...64
TEST ALTERNATOR BELT...67
TEST ALTERNATOR BELT TENSION...67
TEST AUTOMATIC TENSIONER...69
TEST AUTOMATIC TENSIONER...69
CLEAN FUEL DOSER...72
CLEAN FUEL DOSER...72
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER...74
WRITE INJECTOR COMPENSATION VALUE...74
WRITE CORRECTION FOR ASH IN SOOT ACCUMULATION TO ENGINE CONTROLLER...81
WRITE CORRECTION FOR ASH IN SOOT ACCUMULATION TO ENGINE CONTROLLER...81
TEST SCR RELATED FUNCTION...82
TEST AdBlue/DEF PUMP RAISED PRESSURE...86
TEST INJECTION VOLUME FROM AdBlue/DEF INJECTOR...90
TEST AdBlue/DEF LINE HEATER RELAY 1...96
TEST AdBlue/DEF LINE HEATER RELAY 2...100
TEST AdBlue/DEF PUMP HEATER RELAY...104
TEST AdBlue/DEF TANK HEATER VALVE...109
TEST SCR DENITRATION EFFICIENCY...113
CLEAN AdBlue/DEF TANK...118
CLEAN AdBlue/DEF TANK...118
POWER TRAIN...123
TEST AND ADJUST POWER TRAIN OIL PRESSURE...123
TEST POWER TRAIN OIL PRESSURE...126
TEST AND ADJUST HST OIL PRESSURE...144
TEST HST OIL PRESSURE...144
ADJUST HST OIL PRESSURE...148
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR...149
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR...149
ADJUST TRANSMISSION M2 SPEED SENSOR...151
ADJUST TRANSMISSION M2 SPEED SENSOR...151
FLUSH TRANSMISSION HYDRAULIC CIRCUIT...153
FLUSH TRANSMISSION HYDRAULIC CIRCUIT...153
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE...155
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE...155
TRAVEL WHEN ELECTRIC SYSTEM FAILS...156
STEERING SYSTEM...158
TEST STEERING WHEEL...158
TEST STEERING WHEEL...158
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE...161
TEST STEERING CIRCUIT OIL PRESSURE...161
ADJUST STEERING CIRCUIT OIL PRESSURE...168
BLEED AIR FROM STEERING CYLINDER CIRCUIT...169
BLEED AIR FROM STEERING CYLINDER CIRCUIT...169
TEST AND ADJUST STEERING STOP VALVE...170
TEST STEERING STOP VALVE...170
ADJUST STEERING STOP VALVE...170
BRAKE SYSTEM...172
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT...172
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT...172
TEST WHEEL BRAKE OIL PRESSURE...173
TEST WHEEL BRAKE OIL PRESSURE...173
TEST AND ADJUST ACCUMULATOR CHARGE PRESSURE...176
TEST ACCUMULATOR CHARGE PRESSURE...176
ADJUST ACCUMULATOR CHARGE PRESSURE...177
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE...179
TEST ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE...179
CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE...182
RELEASE NITROGEN GAS WHEN YOU DISPOSE OF ACCUMULATOR...186
BLEED AIR FROM BRAKE CIRCUIT...188
BLEED AIR FROM BRAKE CIRCUIT...188
TEST BRAKE PERFORMANCE...191
TEST BRAKE PERFORMANCE...191
TEST BRAKE PEDAL...192
TEST BRAKE PEDAL...192
TEST PRESSURE DECREASE OF WHEEL BRAKE...194
TEST PRESSURE DECREASE OF WHEEL BRAKE BY BRAKE TESTER...195
TEST PRESSURE DECREASE OF WHEEL BRAKE WHEN ENGINE IS RUNNING...197
TEST WEAR OF WHEEL BRAKE DISC...198
TEST WEAR OF WHEEL BRAKE DISC...198
TEST PARKING BRAKE OIL PRESSURE...200
TEST PARKING BRAKE OIL PRESSURE...200
TEST PARKING BRAKE PERFORMANCE...202
TEST PARKING BRAKE PERFORMANCE...202
RELEASE PARKING BRAKE MANUALLY...203
RELEASE PARKING BRAKE MANUALLY...203
TEST WEAR AMOUNT OF PARKING BRAKE DISC...206
TEST WEAR AMOUNT OF PARKING BRAKE DISC...206
HYDRAULIC SYSTEM...207
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT...207
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT...207
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE...209
TEST WORK EQUIPMENT OIL PRESSURE...209
ADJUST WORK EQUIPMENT OIL PRESSURE...215
TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE...217
TEST WORK EQUIPMENT EPC OIL PRESSURE...217
ADJUST WORK EQUIPMENT EPC OIL PRESSURE...221
BLEED AIR FROM WORK EQUIPMENT CIRCUIT...223
BLEED AIR FROM WORK EQUIPMENT PUMP...223
BLEED AIR FROM WORK EQUIPMENT CYLINDER...224
TEST COOLING FAN SPEED...225
TEST COOLING FAN SPEED...225
TEST COOLING FAN CIRCUIT OIL PRESSURE...227
TEST COOLING FAN CIRCUIT OIL PRESSURE...227
BLEED AIR FROM COOLING FAN CIRCUIT...231
BLEED AIR FROM COOLING FAN CIRCUIT...231
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS...233
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE...233
CHARGE ECSS ACCUMULATOR WITH NITROGEN GAS...235
WORK EQUIPMENT...239
TEST AND ADJUST BUCKET POTENTIOMETER LEVER...239
TEST BUCKET POTENTIOMETER LEVER...239
ADJUST BUCKET POTENTIOMETER LEVER...240
TEST AND ADJUST BOOM POTENTIOMETER LEVER...241
TEST BOOM POTENTIOMETER LEVER...241
ADJUST BOOM POTENTIOMETER LEVER...242
CAB RELATED PARTS...243
TEST DIRECTIONAL LEVER...243
TEST DIRECTIONAL LEVER...243
TEST WORK EQUIPMENT CONTROL LEVER...244
TEST WORK EQUIPMENT CONTROL LEVER...244
TEST AJSS LEVER (AJSS SPECIFICATIONS)...248
TEST AJSS LEVER...248
TEST STEERING LOCK LEVER (AJSS SPECIFICATION)...251
TEST STEERING LOCK LEVER...251
TEST AND ADJUST AJSS LEVER ANGLE SENSOR AND AJSS FRAME ANGLE SENSOR (AJSS SPECIFICATIONS)...252
TEST AJSS LEVER ANGLE SENSOR AND AJSS FRAME ANGLE SENSOR...252
ADJUST AJSS LEVER ANGLE SENSOR AND AJSS FRAME ANGLE SENSOR...252
TEST AND ADJUST STEERING STOPPER BOLT (AJSS SPECIFICATIONS)...256
TEST STEERING STOPPER BOLT...256
ADJUST STEERING STOPPER BOLT...256
ADJUST PLAY OF OPERATOR'S SEAT...257
ADJUST PLAY OF OPERATOR'S SEAT...257
ADJUST MIRRORS...258
ADJUST MIRRORS...258
ELECTRICAL SYSTEM...260
SETTING AND ADJUSTMENT OF EACH EQUIPMENT...260
SET AND OPERATE MACHINE MONITOR...264
OPERATOR MODE...268
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN...268
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN...268
CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)...269
CHECK FUNCTION OF SERVICE METER AND ODOMETER...270
USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD...270
SERVICE MODE...275
SERVICE MODE...275
CHECK PRE-DEFINED MONITORING INFORMATION...279
CHECK MONITORING INFORMATION...296
ABNORMALITY RECORD MENU...315
CHECK MAINTENANCE RECORD...321
MAINTENANCE MODE SETTING...323
SET PHONE NUMBER ENTRY...329
DEFAULT SETTING MENU...331
TESTING MENU...348
ADJUSTMENT MENU...362
NO-INJECTION CRANKING OPERATION...438
KOMTRAX SETTINGS MENU...441
DISPLAY SERVICE MESSAGE...445
START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...447
STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...453
ADJUST REARVIEW CAMERA ANGLE...455
ADJUST REARVIEW CAMERA ANGLE...455
SET REGION OF Bluetooth(R) COMPATIBLE RADIO...458
SET REGION OF Bluetooth(R) COMPATIBLE RADIO...458
ENGINE CONTROLLER VOLTAGE CIRCUIT...460
BATTERY DISCONNECT SWITCH...461
TEST DIODES...462
TEST DIODES BY DIGITAL TESTER...462
TEST DIODES BY ANALOG TESTER...462
AUTO-GREASING SYSTEM...463
BLEED THE AIR IN AUTO-GREASING SYSTEM...463
BLEED THE AIR IN AUTO-GREASING SYSTEM...463
CORRESPONDENCE IN CASE OF GREASE LEAKAGE FROM OVER PRESSURE PROTECTION VALVE...466
CORRESPONDENCE IN CASE OF GREASE LEAKAGE FROM OVER PRESSURE PROTECTION VALVE...466
CHANGE LUBRICATION TIME AND LUBRICATION INTERVAL...467
CHANGE LUBRICATION TIME AND LUBRICATION INTERVAL...468
Pm-CLINIC...470
Pm CLINIC SERVICE...470
PM CLINIC CHECK SHEET: WA475-10...472
PM CLINIC CHECK SHEET: WA475-10E0...484
40 TROUBLESHOOTING...1
CONTENTS...2
RELATED INFORMATION TO TROUBLESHOOT...18
PRECAUTIONS FOR TROUBLESHOOTING...18
SEQUENCE OF EVENTS IN TROUBLESHOOTING...19
GENERAL TROUBLESHOOTING POINTS...21
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM...22
CHECKS BEFORE TROUBLESHOOTING...34
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING...36
WALK-AROUND CHECK...36
TESTING IN ACCORDANCE WITH TESTING PROCEDURE...38
CHECK FUEL LEVEL AND TYPE...38
CHECK IMPURE INGREDIENT IN FUEL...38
CHECK AdBlue® LEVEL AND TYPE...39
CHECK FUEL PREFILTER...39
CHECK FUEL MAIN FILTER...41
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE...42
CHECK COOLANT LEVEL(EXPANSION TANK)...43
CHECK AIR CLEANER CLOGGING...44
CLEAN OUTER ELEMENT...45
REPLACE ELEMENT...46
Check hydraulic oil level...47
CHECK HYDRAULIC OIL STRAINER...48
CHECK HYDRAULIC OIL FILTER...50
CHECK OIL LEVEL IN TRANSMISSION CASE...52
Check front axle case oil level...53
Check rear axle case oil level...54
BLEED AIR FROM FUEL SYSTEM...55
BLEED AIR FROM HYDRAULIC SYSTEM...55
CHECK ELECTRIC EQUIPMENT...55
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM...62
PROCEDURE FOR TROUBLESHOOTING...72
ADJUSTMENT AFTER TROUBLESHOOTING...75
SYMPTOM AND TROUBLESHOOTING NUMBERS...77
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...82
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM...84
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE...87
CONNECTOR LAYOUT...100
CONNECTOR CONTACT IDENTIFICATION...111
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE...153
FUSE LOCATION TABLE...159
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)...163
PREPARATION TO TROUBLESHOOT MACHINE MONITOR...167
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT...169
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])...175
FAILURE CODE TABLE...177
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)...204
FAILURE CODE [1500L0]...204
FAILURE CODE [1500MA]...205
FAILURE CODE [1500MC]...206
FAILURE CODE [1AR0MA]...207
FAILURE CODE [2F00MA]...208
FAILURE CODE [2F00MB]...212
FAILURE CODE [2G42ZG]...215
FAILURE CODE [2G43ZG]...217
FAILURE CODE [6071NX]...219
FAILURE CODE [879AKA]...221
FAILURE CODE [879AKB]...223
FAILURE CODE [879BKA]...225
FAILURE CODE [879BKB]...227
FAILURE CODE [879CKA]...229
FAILURE CODE [879CKB]...231
FAILURE CODE [879DKZ]...233
FAILURE CODE [879EMC]...235
FAILURE CODE [879FMC]...238
FAILURE CODE [989A00]...241
FAILURE CODE [989L00]...242
FAILURE CODE [989M00]...243
FAILURE CODE [989N00]...244
FAILURE CODE [A1U0N3]...245
FAILURE CODE [A1U0N4]...247
FAILURE CODE [AA10NX]...249
FAILURE CODE [AB00KE]...251
FAILURE CODE [AB00KY]...253
FAILURE CODE [AQ10N3]...255
FAILURE CODE [AS00N3]...257
FAILURE CODE [AS00R2]...259
FAILURE CODE [AS00R3]...260
FAILURE CODE [AS00R4]...261
FAILURE CODE [AS00R5]...262
FAILURE CODE [AS00R6]...263
FAILURE CODE [AS00ZK]...264
FAILURE CODE [AS10KM]...265
FAILURE CODE [AS10NR]...266
FAILURE CODE [AS10NT]...267
FAILURE CODE [B@BAZK]...268
FAILURE CODE [B@BCQA]...270
FAILURE CODE [B@BCZK]...272
FAILURE CODE [B@C6NS]...274
FAILURE CODE [B@CFNS]...276
FAILURE CODE [B@HANS]...278
FAILURE CODE [CA115]...279
FAILURE CODE [CA122]...280
FAILURE CODE [CA123]...282
FAILURE CODE [CA131]...284
FAILURE CODE [CA132]...286
FAILURE CODE [CA135]...289
FAILURE CODE [CA141]...291
FAILURE CODE [CA144]...293
FAILURE CODE [CA145]...295
FAILURE CODE [CA153]...297
FAILURE CODE [CA154]...300
FAILURE CODE [CA187]...303
FAILURE CODE [CA221]...305
FAILURE CODE [CA222]...307
FAILURE CODE [CA227]...309
FAILURE CODE [CA234]...310
FAILURE CODE [CA238]...311
FAILURE CODE [CA239]...313
FAILURE CODE [CA249]...315
FAILURE CODE [CA256]...317
FAILURE CODE [CA271]...319
FAILURE CODE [CA272]...321
FAILURE CODE [CA273]...322
FAILURE CODE [CA274]...324
FAILURE CODE [CA322]...325
FAILURE CODE [CA323]...327
FAILURE CODE [CA324]...329
FAILURE CODE [CA325]...331
FAILURE CODE [CA331]...333
FAILURE CODE [CA332]...335
FAILURE CODE [CA343]...337
FAILURE CODE [CA351]...338
FAILURE CODE [CA352]...339
FAILURE CODE [CA356]...342
FAILURE CODE [CA357]...344
FAILURE CODE [CA386]...346
FAILURE CODE [CA431]...347
FAILURE CODE [CA432]...350
FAILURE CODE [CA441]...354
FAILURE CODE [CA442]...356
FAILURE CODE [CA449]...357
FAILURE CODE [CA451]...358
FAILURE CODE [CA452]...360
FAILURE CODE [CA515]...362
FAILURE CODE [CA516]...364
FAILURE CODE [CA553]...366
FAILURE CODE [CA555]...367
FAILURE CODE [CA556]...368
FAILURE CODE [CA559]...369
FAILURE CODE [CA595]...374
FAILURE CODE [CA687]...375
FAILURE CODE [CA689]...377
FAILURE CODE [CA691]...379
FAILURE CODE [CA692]...381
FAILURE CODE [CA697]...383
FAILURE CODE [CA698]...384
FAILURE CODE [CA731]...385
FAILURE CODE [CA778]...386
FAILURE CODE [CA1117]...389
FAILURE CODE [CA1664]...390
FAILURE CODE [CA1669]...393
FAILURE CODE [CA1673]...394
FAILURE CODE [CA1677]...395
FAILURE CODE [CA1678]...396
FAILURE CODE [CA1682]...397
FAILURE CODE [CA1683]...401
FAILURE CODE [CA1684]...403
FAILURE CODE [CA1686]...405
FAILURE CODE [CA1691]...406
FAILURE CODE [CA1694]...409
FAILURE CODE [CA1695]...411
FAILURE CODE [CA1696]...412
FAILURE CODE [CA1712]...414
FAILURE CODE [CA1713]...417
FAILURE CODE [CA1714]...419
FAILURE CODE [CA1715]...420
FAILURE CODE [CA1776]...421
FAILURE CODE [CA1777]...424
FAILURE CODE [CA1843]...427
FAILURE CODE [CA1844]...429
FAILURE CODE [CA1879]...432
FAILURE CODE [CA1881]...435
FAILURE CODE [CA1883]...437
FAILURE CODE [CA1885]...441
FAILURE CODE [CA1887]...443
FAILURE CODE [CA1921]...445
FAILURE CODE [CA1922]...448
FAILURE CODE [CA1923]...453
FAILURE CODE [CA1924]...455
FAILURE CODE [CA1925]...457
FAILURE CODE [CA1927]...459
FAILURE CODE [CA1928]...461
FAILURE CODE [CA1942]...463
FAILURE CODE [CA1963]...464
FAILURE CODE [CA1977]...471
FAILURE CODE [CA1993]...474
FAILURE CODE [CA2185]...477
FAILURE CODE [CA2186]...479
FAILURE CODE [CA2249]...481
FAILURE CODE [CA2265]...482
FAILURE CODE [CA2266]...485
FAILURE CODE [CA2271]...488
FAILURE CODE [CA2272]...490
FAILURE CODE [CA2349]...492
FAILURE CODE [CA2353]...494
FAILURE CODE [CA2357]...496
FAILURE CODE [CA2381]...497
FAILURE CODE [CA2382]...499
FAILURE CODE [CA2383]...501
FAILURE CODE [CA2386]...503
FAILURE CODE [CA2387]...505
FAILURE CODE [CA2555]...506
FAILURE CODE [CA2556]...508
FAILURE CODE [CA2637]...510
FAILURE CODE [CA2639]...512
FAILURE CODE [CA2732]...515
FAILURE CODE [CA2733]...517
FAILURE CODE [CA2741]...519
FAILURE CODE [CA2765]...520
FAILURE CODE [CA2771]...521
FAILURE CODE [CA2777]...527
FAILURE CODE [CA2878]...530
FAILURE CODE [CA2881]...533
FAILURE CODE [CA2976]...538
FAILURE CODE [CA3133]...540
FAILURE CODE [CA3134]...542
FAILURE CODE [CA3135]...544
FAILURE CODE [CA3142]...547
FAILURE CODE [CA3143]...548
FAILURE CODE [CA3144]...549
FAILURE CODE [CA3146]...552
FAILURE CODE [CA3147]...553
FAILURE CODE [CA3148]...554
FAILURE CODE [CA3151]...557
FAILURE CODE [CA3165]...563
FAILURE CODE [CA3167]...565
FAILURE CODE [CA3229]...568
FAILURE CODE [CA3231]...570
FAILURE CODE [CA3232]...572
FAILURE CODE [CA3235]...576
FAILURE CODE [CA3239]...578
FAILURE CODE [CA3241]...581
FAILURE CODE [CA3242]...584
FAILURE CODE [CA3251]...587
FAILURE CODE [CA3253]...589
FAILURE CODE [CA3254]...592
FAILURE CODE [CA3255]...595
FAILURE CODE [CA3256]...599
FAILURE CODE [CA3311]...601
FAILURE CODE [CA3312]...603
FAILURE CODE [CA3313]...606
FAILURE CODE [CA3314]...607
FAILURE CODE [CA3315]...608
FAILURE CODE [CA3316]...611
FAILURE CODE [CA3317]...612
FAILURE CODE [CA3318]...613
FAILURE CODE [CA3319]...616
FAILURE CODE [CA3321]...617
FAILURE CODE [CA3322]...619
FAILURE CODE [CA3419]...622
FAILURE CODE [CA3421]...624
FAILURE CODE [CA3497]...626
FAILURE CODE [CA3498]...627
FAILURE CODE [CA3543]...628
FAILURE CODE [CA3545]...635
FAILURE CODE [CA3547]...637
FAILURE CODE [CA3558]...638
FAILURE CODE [CA3559]...640
FAILURE CODE [CA3562]...642
FAILURE CODE [CA3563]...644
FAILURE CODE [CA3567]...647
FAILURE CODE [CA3568]...650
FAILURE CODE [CA3571]...656
FAILURE CODE [CA3572]...658
FAILURE CODE [CA3574]...660
FAILURE CODE [CA3575]...662
FAILURE CODE [CA3577]...664
FAILURE CODE [CA3578]...666
FAILURE CODE [CA3582]...668
FAILURE CODE [CA3583]...676
FAILURE CODE [CA3596]...678
FAILURE CODE [CA3649]...681
FAILURE CODE [CA3681]...683
FAILURE CODE [CA3682]...688
FAILURE CODE [CA3713]...694
FAILURE CODE [CA3717]...697
FAILURE CODE [CA3718]...698
FAILURE CODE [CA3725]...699
FAILURE CODE [CA3748]...702
FAILURE CODE [CA3751]...705
FAILURE CODE [CA3755]...707
FAILURE CODE [CA3866]...709
FAILURE CODE [CA3867]...713
FAILURE CODE [CA3868]...716
FAILURE CODE [CA3899]...720
FAILURE CODE [CA3911]...722
FAILURE CODE [CA3912]...726
FAILURE CODE [CA3932]...728
FAILURE CODE [CA3933]...730
FAILURE CODE [CA3934]...732
FAILURE CODE [CA3935]...735
FAILURE CODE [CA3936]...737
FAILURE CODE [CA4151]...739
FAILURE CODE [CA4152]...743
FAILURE CODE [CA4155]...747
FAILURE CODE [CA4156]...749
FAILURE CODE [CA4157]...752
FAILURE CODE [CA4158]...754
FAILURE CODE [CA4159]...755
FAILURE CODE [CA4161]...756
FAILURE CODE [CA4162]...759
FAILURE CODE [CA4163]...762
FAILURE CODE [CA4164]...764
FAILURE CODE [CA4165]...766
FAILURE CODE [CA4166]...768
FAILURE CODE [CA4168]...770
FAILURE CODE [CA4169]...773
FAILURE CODE [CA4171]...775
FAILURE CODE [CA4249]...778
FAILURE CODE [CA4251]...780
FAILURE CODE [CA4259]...782
FAILURE CODE [CA4261]...785
FAILURE CODE [CA4277]...788
FAILURE CODE [CA4281]...792
FAILURE CODE [CA4459]...795
FAILURE CODE [CA4461]...798
FAILURE CODE [CA4731]...801
FAILURE CODE [CA4732]...802
FAILURE CODE [CA4739]...803
FAILURE CODE [CA4768]...804
FAILURE CODE [CA4769]...806
FAILURE CODE [CA4842]...809
FAILURE CODE [CA4952]...813
FAILURE CODE [CA5115]...815
FAILURE CODE [CA5179]...818
FAILURE CODE [CA5181]...820
FAILURE CODE [CA5383]...822
FAILURE CODE [D110KB]...824
FAILURE CODE [D150KA]...826
FAILURE CODE [D150KB]...828
FAILURE CODE [D150KY]...830
FAILURE CODE [D160KA]...832
FAILURE CODE [D160KB]...834
FAILURE CODE [D160KY]...836
FAILURE CODE [D191KA]...838
FAILURE CODE [D191KB]...841
FAILURE CODE [D191KY]...844
FAILURE CODE [D192KA]...846
FAILURE CODE [D192KB]...848
FAILURE CODE [D192KY]...850
FAILURE CODE [D19JKZ]...852
FAILURE CODE [D1E6KA]...854
FAILURE CODE [D1E6KB]...856
FAILURE CODE [D1E6KY]...858
FAILURE CODE [D1Q1KA]...860
FAILURE CODE [D1Q1KB]...862
FAILURE CODE [D1Q1KY]...864
FAILURE CODE [D1Q1MC]...865
FAILURE CODE [D5ZHKA]...867
FAILURE CODE [D5ZHKB]...869
FAILURE CODE [D5ZHKZ]...871
FAILURE CODE [D5ZHL6]...874
FAILURE CODE [D811MC]...876
FAILURE CODE [D862KA]...877
FAILURE CODE [D8ALKA]...878
FAILURE CODE [D8ALKB]...880
FAILURE CODE [D8AQK4]...882
FAILURE CODE [D8AQKR]...883
FAILURE CODE [D8ARKR]...885
FAILURE CODE [D8G1KT]...887
FAILURE CODE [D8G6KT]...888
FAILURE CODE [DAF0KT]...889
FAILURE CODE [DAF0MB]...890
FAILURE CODE [DAF0MC]...891
FAILURE CODE [DAF3KK]...892
FAILURE CODE [DAF8KB]...894
FAILURE CODE [DAFDKB]...895
FAILURE CODE [DAFGMC]...897
FAILURE CODE [DAFLKA]...898
FAILURE CODE [DAFLKB]...900
FAILURE CODE [DAFQKR]...902
FAILURE CODE [DAQ0KK]...903
FAILURE CODE [DAQ0KT]...906
FAILURE CODE [DAQ0MC]...907
FAILURE CODE [DAQ1KA]...908
FAILURE CODE [DAQ2KK]...910
FAILURE CODE [DAQ4KB]...913
FAILURE CODE [DAQ9KQ]...915
FAILURE CODE [DAQLKA]...916
FAILURE CODE [DAQLKB]...918
FAILURE CODE [DAQQKR]...920
FAILURE CODE [DAQRKR]...921
FAILURE CODE [DAQRMA]...922
FAILURE CODE [DAZ9KQ]...923
FAILURE CODE [DAZQKR]...924
FAILURE CODE [DB2QKR]...925
FAILURE CODE [DB2RKR]...933
FAILURE CODE [DB90KK]...940
FAILURE CODE [DB90KT]...943
FAILURE CODE [DB90MC]...944
FAILURE CODE [DB91KA]...945
FAILURE CODE [DB92KK]...947
FAILURE CODE [DB95KX]...950
FAILURE CODE [DB96KX]...953
FAILURE CODE [DB99KQ]...955
FAILURE CODE [DB9LKA]...956
FAILURE CODE [DB9LKB]...958
FAILURE CODE [DB9QKR]...960
FAILURE CODE [DB9RKR]...961
FAILURE CODE [DB9RMA]...962
FAILURE CODE [DBE5KX]...963
FAILURE CODE [DBE6KX]...965
FAILURE CODE [DBE7KX]...967
FAILURE CODE [DD61LD]...969
FAILURE CODE [DDAAL6]...971
FAILURE CODE [DDB6L4]...973
FAILURE CODE [DDK3KA]...976
FAILURE CODE [DDK3KB]...979
FAILURE CODE [DDK4KA]...982
FAILURE CODE [DDK4KB]...985
FAILURE CODE [DDK6KA]...987
FAILURE CODE [DDK6KB]...990
FAILURE CODE [DDKLKA]...993
FAILURE CODE [DDKLKB]...995
FAILURE CODE [DDNRKA]...997
FAILURE CODE [DDNRKY]...1000
FAILURE CODE [DDP5KA]...1002
FAILURE CODE [DDUAKR]...1004
FAILURE CODE [DDUBKR]...1008
FAILURE CODE [DDUCKR]...1012
FAILURE CODE [DF50KA]...1016
FAILURE CODE [DF50KY]...1018
FAILURE CODE [DGF1KA]...1020
FAILURE CODE [DGF1KB]...1022
FAILURE CODE [DGH2KA]...1024
FAILURE CODE [DGH2KX]...1026
FAILURE CODE [DGH4KA]...1028
FAILURE CODE [DGH4KX]...1030
FAILURE CODE [DGR4KB]...1032
FAILURE CODE [DGR4KZ]...1034
FAILURE CODE [DH21KA]...1036
FAILURE CODE [DH21KB]...1039
FAILURE CODE [DHA4KA]...1042
FAILURE CODE [DHHBKA]...1044
FAILURE CODE [DHHBKY]...1046
FAILURE CODE [DHHCKA]...1048
FAILURE CODE [DHHCKY]...1050
FAILURE CODE [DHPCKA]...1052
FAILURE CODE [DHPCKY]...1054
FAILURE CODE [DHPDKA]...1056
FAILURE CODE [DHPDKY]...1058
FAILURE CODE [DHT1KX]...1060
FAILURE CODE [DHT8KA]...1062
FAILURE CODE [DHT8KB]...1065
FAILURE CODE [DHT8ZG]...1067
FAILURE CODE [DHTCL6]...1068
FAILURE CODE [DHUDKA]...1070
FAILURE CODE [DHUDKB]...1073
FAILURE CODE [DJF1KA]...1075
FAILURE CODE [DK30KA]...1077
FAILURE CODE [DK30KY]...1079
FAILURE CODE [DK55KA]...1081
FAILURE CODE [DK55KY]...1084
FAILURE CODE [DK55L5]...1086
FAILURE CODE [DK59KA]...1087
FAILURE CODE [DK59KY]...1091
FAILURE CODE [DK59L8]...1095
FAILURE CODE [DK5AKA]...1100
FAILURE CODE [DK5AKY]...1104
FAILURE CODE [DK5BKA]...1108
FAILURE CODE [DK5BKY]...1112
FAILURE CODE [DK5BL8]...1116
FAILURE CODE [DK5CKA]...1121
FAILURE CODE [DK5CKY]...1125
FAILURE CODE [DK5DKA]...1129
FAILURE CODE [DK5DKY]...1133
FAILURE CODE [DK5DL8]...1137
FAILURE CODE [DK5EKA]...1142
FAILURE CODE [DK5EKY]...1146
FAILURE CODE [DK60KB]...1150
FAILURE CODE [DK60KR]...1151
FAILURE CODE [DK70KA]...1154
FAILURE CODE [DK70KY]...1157
FAILURE CODE [DK71KA]...1160
FAILURE CODE [DK71KY]...1163
FAILURE CODE [DK72KA]...1166
FAILURE CODE [DK72L8]...1167
FAILURE CODE [DKA0KA]...1171
FAILURE CODE [DKA0KY]...1174
FAILURE CODE [DKA0L0]...1177
FAILURE CODE [DKA1KA]...1180
FAILURE CODE [DKA1KY]...1183
FAILURE CODE [DKD0KA]...1186
FAILURE CODE [DKD0KY]...1188
FAILURE CODE [DKD0L8]...1190
FAILURE CODE [DKR0KA]...1191
FAILURE CODE [DKR0KB]...1194
FAILURE CODE [DKR1KA]...1196
FAILURE CODE [DKR1KB]...1199
FAILURE CODE [DKR2KX]...1201
FAILURE CODE [DKR2NX]...1202
FAILURE CODE [DKR5KA]...1204
FAILURE CODE [DKR5KB]...1207
FAILURE CODE [DLF1KA]...1209
FAILURE CODE [DLF1LC]...1211
FAILURE CODE [DLM0KA]...1213
FAILURE CODE [DLM0LC]...1215
FAILURE CODE [DLM3KA]...1217
FAILURE CODE [DLM3LC]...1219
FAILURE CODE [DLT3KX]...1221
FAILURE CODE [DLT4KX]...1223
FAILURE CODE [DLT4L0]...1225
FAILURE CODE [DPQ2KR]...1226
FAILURE CODE [DPQ3KR]...1229
FAILURE CODE [DSJ0KR]...1232
FAILURE CODE [DV00KB]...1235
FAILURE CODE [DV20KB]...1237
FAILURE CODE [DV20KY]...1239
FAILURE CODE [DW4PKA]...1240
FAILURE CODE [DW4PKB]...1242
FAILURE CODE [DW4PKY]...1244
FAILURE CODE [DW4QKA]...1246
FAILURE CODE [DW4QKB]...1248
FAILURE CODE [DW4QKY]...1250
FAILURE CODE [DW4RKA]...1252
FAILURE CODE [DW4RKB]...1254
FAILURE CODE [DW4RKY]...1256
FAILURE CODE [DW4SKA]...1258
FAILURE CODE [DW4SKB]...1260
FAILURE CODE [DW4SKY]...1262
FAILURE CODE [DW7BKA]...1264
FAILURE CODE [DW7BKB]...1266
FAILURE CODE [DW7BKY]...1268
FAILURE CODE [DWM1KA]...1270
FAILURE CODE [DWM1KB]...1272
FAILURE CODE [DWM1KY]...1274
FAILURE CODE [DWR1KA]...1276
FAILURE CODE [DWR1KB]...1278
FAILURE CODE [DWR1KY]...1280
FAILURE CODE [DWR2KA]...1282
FAILURE CODE [DWR2KB]...1283
FAILURE CODE [DWR2KY]...1284
FAILURE CODE [DWRAKA]...1285
FAILURE CODE [DWRAKB]...1286
FAILURE CODE [DWRAKY]...1287
FAILURE CODE [DWRBKA]...1288
FAILURE CODE [DWRBKB]...1290
FAILURE CODE [DWRBKY]...1292
FAILURE CODE [DWRCKA]...1293
FAILURE CODE [DWRCKB]...1295
FAILURE CODE [DWRCKY]...1297
FAILURE CODE [DWRDKA]...1298
FAILURE CODE [DWRDKB]...1300
FAILURE CODE [DWRDKY]...1302
FAILURE CODE [DWREKA]...1304
FAILURE CODE [DWREKB]...1306
FAILURE CODE [DWREKY]...1308
FAILURE CODE [DWRFKA]...1310
FAILURE CODE [DWRFKB]...1312
FAILURE CODE [DWRFKY]...1314
FAILURE CODE [DWRGKA]...1316
FAILURE CODE [DWRGKB]...1318
FAILURE CODE [DWRGKY]...1320
FAILURE CODE [DWRHKA]...1322
FAILURE CODE [DWRHKB]...1324
FAILURE CODE [DWRHKY]...1326
FAILURE CODE [DWRJKA]...1328
FAILURE CODE [DWRJKB]...1330
FAILURE CODE [DWRJKY]...1332
FAILURE CODE [DWRKKA]...1334
FAILURE CODE [DWRKKB]...1336
FAILURE CODE [DWRKKY]...1338
FAILURE CODE [DWRLKA]...1340
FAILURE CODE [DWRLKB]...1342
FAILURE CODE [DWRLKY]...1344
FAILURE CODE [DX16KA]...1346
FAILURE CODE [DX16KB]...1348
FAILURE CODE [DX16KY]...1350
FAILURE CODE [DX35KA]...1352
FAILURE CODE [DX35KB]...1354
FAILURE CODE [DX35KY]...1356
FAILURE CODE [DX4PKA]...1358
FAILURE CODE [DX4PKB]...1360
FAILURE CODE [DX4PKY]...1362
FAILURE CODE [DXA1KA]...1364
FAILURE CODE [DXA1KB]...1366
FAILURE CODE [DXA1KY]...1368
FAILURE CODE [DXANKA]...1369
FAILURE CODE [DXANKB]...1371
FAILURE CODE [DXANKY]...1373
FAILURE CODE [DXE2KA]...1375
FAILURE CODE [DXE2KB]...1377
FAILURE CODE [DXE2KY]...1379
FAILURE CODE [DXF0KA]...1380
FAILURE CODE [DXF0KB]...1382
FAILURE CODE [DXF0KY]...1384
FAILURE CODE [DXHJKA]...1386
FAILURE CODE [DXHJKB]...1388
FAILURE CODE [DXHJKY]...1390
FAILURE CODE [DXHKKA]...1392
FAILURE CODE [DXHKKB]...1394
FAILURE CODE [DXHKKY]...1396
FAILURE CODE [DY30MA]...1398
FAILURE CODE [DY30MC]...1402
FAILURE CODE [DY30ME]...1407
FAILURE CODE [F313KA]...1409
FAILURE CODE [F313KB]...1411
FAILURE CODE [F318KB]...1412
FAILURE CODE [F318KY]...1414
FAILURE CODE [F7FQKR]...1415
FAILURE CODE [F7G0MC]...1423
FAILURE CODE [FG11KA]...1424
FAILURE CODE [FG11KY]...1427
FAILURE CODE [FG12KA]...1430
FAILURE CODE [FG12KY]...1433
FAILURE CODE [FG13L0]...1436
FAILURE CODE [FG14MC]...1437
FAILURE CODE [FH11N1]...1438
FAILURE CODE [FH12N1]...1439
FAILURE CODE [FH3100]...1440
FAILURE CODE [FL01KR]...1441
FAILURE CODE [FL02KR]...1442
FAILURE CODE [FL03KR]...1443
FAILURE CODE [FL04KR]...1444
FAILURE CODE [FL05KR]...1445
FAILURE CODE [FL06KR]...1446
FAILURE CODE [FL07KR]...1447
FAILURE CODE [FL08KR]...1448
FAILURE CODE [FL09KR]...1449
FAILURE CODE [FL0AKB]...1450
FAILURE CODE [FL0ALD]...1452
FAILURE CODE [FL0BKB]...1453
FAILURE CODE [FL0BLD]...1455
FAILURE CODE [FL0CKB]...1456
FAILURE CODE [FL0CLD]...1458
FAILURE CODE [FL0DKB]...1459
FAILURE CODE [FL0DLD]...1461
FAILURE CODE [FL0GLD]...1462
FAILURE CODE [FL0HLD]...1463
FAILURE CODE [FL0JLD]...1464
FAILURE CODE [FL0KLD]...1465
FAILURE CODE [FL0LLD]...1466
FAILURE CODE [FL0MLD]...1467
FAILURE CODE [FM10MA]...1468
FAILURE CODE [FM11MA]...1469
FAILURE CODE [FM12MA]...1470
FAILURE CODE [FM13MA]...1471
FAILURE CODE [FM14MA]...1472
FAILURE CODE [LA00L3]...1473
FAILURE CODE [M000NS]...1474
FAILURE CODE [M000ZG]...1475
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...1476
ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...1476
MANUAL PREHEATING SYSTEM DOES NOT WORK...1483
AUTOMATIC PREHEATING SYSTEM DOES NOT OPERATE...1486
WHILE PREHEATING IS IN OPERATION, PREHEATING PILOT LAMP DOES NOT LIGHT UP...1489
ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING...1491
LCD UNIT ON MACHINE MONITOR SHOWS NOTHING...1494
BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL (BACKLIGHT GOES OFF OR FLICKERS)...1497
LCD UNIT ON MACHINE MONITOR IS ABNORMAL...1500
METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL...1503
NIGHT MODE LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL...1506
LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL...1510
SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT SHOWN NORMALLY...1513
AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY...1514
REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS...1517
REARVIEW MONITOR IMAGES ARE NOT SHOWN CLEARLY...1520
REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED...1523
NIGHT MODE LAMP OF REARVIEW MONITOR IS ABNORMAL...1527
AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP...1531
RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP...1533
PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN PARKING BRAKE IS SET TO ON (PARKING) POSITION...1535
BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE IS LOW...1539
BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE IS LOW...1540
FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL...1541
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT RISE OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP...1543
SEATBELT CAUTION LAMP DOES NOT SHOW NORMALLY...1545
ALARM BUZZER DOES NOT SOUND...1546
ALARM BUZZER DOES NOT STOP...1548
TRACTION CONTROL IS NOT RELEASED WHEN ONE-PUSH TRACTION CONTROL SWITCH IS PUSHED...1549
BUCKET POSITIONER DOES NOT WORK WHEN BUCKET CONTROL SWITCH IS PUSHED...1551
PARKING BRAKE DOES NOT OPERATE EVEN IF IT IS APPLIED, OR THE BRAKE DRAGS IN FORWARD OR REVERSE TRAVEL WHEN PARKING BRAKE IS RELEASED...1553
LOADER PUMP IS FIXED TO THE MINIMUM FLOW...1557
DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED...1558
TRACTION CONTROL SETTING CAN NOT SWITCH WHEN TRACTION CONTROL SWITCH IS PUSHED...1559
ECSS DOES NOT OPERATE OR CANNOT BE CANCELED...1560
FUNCTION OF AUTO-DIGGING IS NOT ENABLED OR DISABLED WHEN AUTO-DIGGING SWITCH IS PUSHED...1561
REMOTE BOOM POSITIONER CANNOT BE SET WHEN BOOM POSITIONER SWITCH IS PUSHED...1562
SETTING OF REMOTE BUCKET POSITIONER CAN NOT CHANGE WHEN BUCKET POSITIONER SWITCH IS PUSHED...1563
HORN DOES NOT MAKE SOUND (STEERING WHEEL SPECIFICATION)...1564
HORN DOES NOT MAKE SOUND (AJSS SPECIFICATION)...1567
HORN DOES NOT STOP SOUNDING (STEERING WHEEL SPECIFICATION)...1570
HORN DOES NOT STOP SOUNDING (AJSS SPECIFICATION)...1572
NONE OF HEADLAMP, CLEARANCE LAMP, OR TAIL LAMP LIGHTS UP (STEERING WHEEL SPECIFICATION)...1574
NONE OF HEADLAMP, CLEARANCE LAMP, OR TAIL LAMP LIGHTS UP (AJSS SPECIFICATION)...1576
CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OFF (STEERING WHEEL SPECIFICATION)...1578
CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OFF (AJSS SPECIFICATION)...1582
NEITHER OF LOW BEAM AND HIGH BEAM OF HEADLAMP DO NOT LIGHT UP OR GO OFF (STEERING WHEEL SPECIFICATION)...1586
NEITHER OF LOW BEAM AND HIGH BEAM OF HEADLAMP DO NOT LIGHT UP OR GO OFF (AJSS SPECIFICATION)...1590
LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GOES OFF (STEERING WHEEL SPECIFICATION)...1594
LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GOES OFF (AJSS SPECIFICATION)...1596
HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GOES OFF (STEERING WHEEL SPECIFICATION)...1598
HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GOES OFF (AJSS SPECIFICATION)...1600
FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OFF...1602
FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OFF (EU SPECIFICATIONS)...1606
REAR WORKING LAMP DOES NOT LIGHT UP OR GO OFF...1610
NONE OF TURN SIGNAL LAMPS OR HAZARD LAMP LIGHTS UP OR GOES OFF (STEERING WHEEL SPECIFICATION)...1614
NONE OF TURN SIGNAL LAMPS OR HAZARD LAMP LIGHTS UP OR GOES OFF (STEERING WHEEL SPECIFICATION FOR EU)...1617
NONE OF TURN SIGNAL LAMPS OR HAZARD LAMP LIGHTS UP OR GOES OFF (AJSS SPECIFICATION)...1620
TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OFF (STEERING WHEEL SPECIFICATION)...1623
TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OFF (STEERING WHEEL SPECIFICATION FOR EU)...1626
TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OFF (AJSS SPECIFICATION)...1629
HAZARD LAMP DOES NOT LIGHT UP OR GO OFF (STEERING WHEEL SPECIFICATION)...1632
HAZARD LAMP DOES NOT LIGHT UP OR GO OFF (STEERING WHEEL SPECIFICATION FOR EU)...1636
HAZARD LAMP DOES NOT LIGHT UP OR GO OFF (AJSS SPECIFICATION)...1640
BRAKE LAMP DOES NOT LIGHT UP OR STAYS LIT...1643
BACKUP LAMP DOES NOT LIGHT UP OR STAYS LIT...1647
BACKUP BUZZER DOES NOT SOUND OR DOES NOT STOP...1650
FRONT WIPER DOES NOT OPERATE (STEERING WHEEL SPECIFICATION)...1652
FRONT WIPER DOES NOT OPERATE (AJSS SPECIFICATION)...1656
REAR WIPER DOES NOT OPERATE (STEERING WHEEL SPECIFICATION)...1660
REAR WIPER DOES NOT OPERATE (AJSS SPECIFICATION)...1664
FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY...1668
FAN DOES NOT ROTATE IN REVERSE...1672
FAN DOES NOT ROTATE IN REVERSE...1673
WINDOW WASHER DOES NOT WORK...1674
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...1677
AUTO GREASE PUMP DISPLAY SHOWS [FCS]...1678
AUTO GREASE PUMP DISPLAY SHOWS [FLL]...1680
AUTO GREASE SYSTEM DOES NOT WORK OR STOP...1681
ANGLE OF REAR VIEW MIRROR CAN NOT BE ADJUSTED WHEN ELECTRIC MIRROR ANGLE ADJUSTMENT SWITCH IS OPERATED...1683
HEATER MIRROR DOES NOT WORK OR TURN OFF...1690
REAR HEATED WIRE GLASS DOES NOT WORK OR TURN OFF...1694
POWERED TILTABLE ENGINE HOOD DOES NOT OPEN/CLOSE...1698
COMMAND SELECTOR OPERATION DOES NOT WORK...1703
AIR CONDITIONER PANEL OPERATION DOES NOT WORK...1706
TRAVEL SPEED CONTROL DIAL AND TRAVEL SPEED CONTROL DIAL GAUGE ON MACHINE MONITOR DO NOT MATCH...1709
KEYPAD BACK LIGHT AND PILOT LAMP DO NOT DIM WHEN MONITOR BRIGHTNESS SELECTOR SWITCH IS AT THE NIGHT MODE...1711
BACK LIGHT OF AIR CONDITIONER PANEL DOES NOT DIM WHEN MONITOR BRIGHTNESS SELECTOR SWITCH IS AT THE NIGHT MODE...1713
COMMAND SELECTOR BACK LIGHT AND PILOT LAMP DO NOT DIM WHEN MONITOR BRIGHTNESS SELECTOR SWITCH IS AT THE NIGHT MODE...1715
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...1717
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...1717
FAILURE MODE AND CAUSE TABLE...1718
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW...1764
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 0 TO 1 km/h (DOES NOT MOVE), REVERSE TRAVEL SPEED 0 TO 1 km/h (DOES NOT MOVE))...1765
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 0 TO 1 km/h (DOES NOT MOVE), REVERSE TRAVEL SPEED 0 TO 9 km/h)...1769
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 0 TO 1 km/h (DOES NOT MOVE), REVERSE TRAVEL SPEED 9 TO 26 km/h)...1771
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 0 TO 1 km/h (DOES NOT MOVE), REVERSE TRAVEL SPEED 26 km/h OR MORE (REVERSE TRAVEL IS CORRECT))...1772
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 1 TO 7 km/h, REVERSE TRAVEL SPEED 0 TO 1 km/h (DOES NOT MOVE))...1773
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 1 TO 7 km/h, REVERSE TRAVEL SPEED 1 TO 9 km/h)...1774
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 1 TO 7 km/h, REVERSE TRAVEL SPEED 9 TO 26 km/h)...1778
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 1 TO 7 km/h, REVERSE TRAVEL SPEED 26 km/h OR MORE (REVERSE TRAVEL IS CORRECT))...1779
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 7 TO 14 km/h, REVERSE TRAVEL SPEED 0 TO 1 km/h (DOES NOT MOVE))...1780
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 7 TO 14 km/h, REVERSE TRAVEL SPEED 1 TO 9 km/h)...1781
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 7 TO 14 km/h, REVERSE TRAVEL SPEED 9 TO 26 km/h)...1783
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 7 TO 14 km/h, REVERSE TRAVEL SPEED 26 km/h OR MORE (REVERSE TRAVEL IS CORRECT))...1785
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 14 TO 36 km/h, REVERSE TRAVEL SPEED 0 TO 1 km/h (DOES NOT MOVE))...1786
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 14 TO 36 km/h, REVERSE TRAVEL SPEED 1 TO 9 km/h)...1787
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 14 TO 36 km/h, REVERSE TRAVEL SPEED 9 TO 26 km/h)...1788
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 14 TO 36 km/h, REVERSE TRAVEL SPEED 26 km/h OR MORE (REVERSE TRAVEL IS CORRECT))...1789
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 36 km/h OR MORE (FORWARD TRAVEL IS CORRECT), REVERSE TRAVEL SPEED 0 TO 1 km/h (DOES NOT MOVE))...1790
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 36 km/h OR MORE (FORWARD TRAVEL IS CORRECT), REVERSE TRAVEL SPEED 1 TO 9 km/h)...1791
MACHINE DOES NOT MOVE, OR TRAVEL SPEED IS SLOW (FORWARD TRAVEL SPEED 36 km/h OR MORE (FORWARD TRAVEL IS CORRECT), REVERSE TRAVEL SPEED 9 TO 26 km/h)...1792
NOT SUFFICIENT DRAWBAR PULL...1793
RIM PULL IS WEAK (ONLY IMMEDIATELY AFTER THE MACHINE GOES INTO THE OBJECTIVE MATERIAL)...1794
NOT SUFFICIENT DRAWBAR PULL (ONLY WHEN WORK EQUIPMENT IS IN OPERATION)...1795
INSUFFICIENT DRAWBAR PULL (ONLY WHEN INCREASING TRVEL SPEED, TRAVELING UPHILL AT 0 TO 7 km/h, OR WHEN DOING DIGGING)...1796
INSUFFICIENT DRAWBAR PULL (ONLY WHEN INCREASING TRVEL SPEED, TRAVELING UPHILL AT 7 TO 14 km/h (0 TO 7 km/h IS CORRECT)...1799
STRONG SHOCKS ARE MADE WHEN YOU START MACHINE OR SHIFT GEARS...1800
STRONG SHOCKS ARE MADE WHEN MACHINE MOVES OFF AND DO THE GEAR SHIFT (ONLY WHEN MACHINE MOVES OFF)...1801
STRONG SHOCKS ARE MADE AT MOVE OFF AND GEAR SHIFT (AT ALL GEAR SHIFT)...1803
STRONG SHOCKS ARE MADE AT MOVE OFF AND GEAR SHIFT (SPECIFIED GEAR SHIFT)...1805
NO SHOCK IS MADE AT MOVE OFF AND GEAR SHIFT, BUT TIME LAG IS LARGE...1807
ENGINE SPEED DROPS LARGELY...1810
ENGINE SPEED DECREASES LARGELY (ONLY IMMEDIATELY AFTER MACHINE GOES IN OBJECTIVE MATERIAL)...1811
ENGINE SPEED DROPS LARGELY (ONLY WHEN WORK EQUIPMENT IS IN OPERATION)...1812
ENGINE SPEED DROPS LARGELY (OTHER THAN WHEN IMMEDIATELY AFTER THRUSTING INTO OBJECT OR WHEN WORK EQUIPMENT IS IN OPERATION)...1813
THE BRAKING FORCE OF THE ENGINE BRAKE IS NOT SUFFICIENT (BRAKING FORCE IS WEAK AT DOWNHILL TRAVEL, OR A TIME LAG OCCURS AT DIRECTIONAL SELECTION OPERATION)...1815
THE BRAKING FORCE OF THE ENGINE BRAKE IS NOT SUFFICIENT (BRAKING FORCE IS WEAK AT DOWNHILL TRAVEL, OR A TIME LAG OCCURS AT DIRECTIONAL SELECTION OPERATION) (ONLY WHEN THE TRAVEL SPEED IS BETWEEN 0 AND 7 km/h OR BETWEEN 14 AND 38 km/h)...1816
THE BRAKING FORCE OF THE ENGINE BRAKE IS NOT SUFFICIENT (BRAKING FORCE IS WEAK AT DOWNHILL TRAVEL, OR A TIME LAG OCCURS AT DIRECTIONAL SELECTION OPERATION) (ONLY WHEN THE TRAVEL SPEED IS BETWEEN 7 AND 14 km/h)...1817
THE BRAKING FORCE OF THE ENGINE BRAKE IS NOT SUFFICIENT (BRAKING FORCE IS WEAK AT DOWNHILL TRAVEL, OR TIME LAG OCCURS AT DIRECTIONAL SELECTION OPERATION) (REGARDLESS OF TRAVEL SPEED)...1818
MACHINE DOES NOT TURN (FOR STEERING WHEEL SPEC)...1821
MACHINE DOES NOT TURN (FOR AJSS SPEC)...1823
TURNING RESPONSE IS UNSATISFACTORY (FOR STEERING WHEEL SPEC)...1825
TURNING RESPONSE IS UNSATISFACTORY (AJSS SPECIFICATION)...1827
STEERING WHEEL IS HEAVY TO OPERATE...1829
MACHINE SWAYS OR STRONG SHOCKS ARE MADE WHILE MACHINE TURNS (FOR STEERING WHEEL SPEC)...1830
MACHINE SWAYS OR STRONG SHOCKS ARE MADE WHILE MACHINE TURNS (FOR AJSS SPEC)...1832
TURNING RADIUS IS DIFFERENT ON THE LEFT AND RIGHT...1834
WHEEL BRAKES DO NOT OPERATE OR ARE WEAK...1835
WHEEL BRAKES ARE NOT RELEASED OR DRAG...1837
PARKING BRAKE DOES NOT OPERATE OR IS WEAK...1838
PARKING BRAKE IS NOT RELEASED OR DRAGS...1839
BOOM DOES NOT RISE...1841
BOOM MOVES SLOW OR LACKS LIFTING FORCE...1844
RISING BOOM SLOWS DOWN AT SPECIFIED HEIGHT...1847
LIFT CYLINDER DOES NOT HOLD BUCKET ON GROUND...1848
HYDRAULIC DRIFT OF BOOM IS LARGE...1850
BOOM MOVES UP AND DOWN DURING OPERATION...1851
BUCKET DOES NOT TILT BACK...1852
BUCKET MOVES SLOW OR LACKS TILT BACK FORCE...1855
BUCKET SLOWS DOWN DURING TILT BACK OR DUMP OPERATION...1858
BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND...1859
HYDRAULIC DRIFT OF BUCKET IS LARGE...1861
BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IS IN HOLD)...1862
BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE...1863
ENGINE SPEED FALLS LARGELY OR ENGINE STOPS WHEN YOU OPERATE WORK EQUIPMENT...1864
STRONG SHOCKS ARE MADE WHEN YOU MOVE OR STOP WORK EQUIPMENT...1866
WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES...1869
ECSS DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES...1870
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT ROTATE)...1871
UNUSUAL NOISE IS HEARD FROM AROUND FAN...1873
TROUBLESHOOTING OF ENGINE (S-MODE)...1874
INFORMATION GIVEN IN TROUBLESHOOTING TABLE (S MODE)...1874
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION...1875
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT...1876
FUEL IS SPRAYED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)...1877
ENGINE STARTABILITY IS UNSATISFACTORY...1878
ENGINE DOES NOT PICK UP SMOOTHLY...1880
ENGINE STOPS DURING OPERATION...1882
ENGINE RUNS ROUGH OR IS NOT STABLE...1884
ENGINE LACKS POWER...1885
KDPF GETS CLOGGED IN A SHORT TIME...1887
ENGINE OIL CONSUMPTION IS EXCESSIVE...1889
OIL BECOMES CONTAMINATED QUICKLY...1890
FUEL CONSUMPTION IS EXCESSIVE...1891
OIL MIXES INTO COOLANT (OR COOLANT SPURTS BACK AND COOLANT LEVEL DOES DOWN)...1892
ENGINE OIL PRESSURE DROPS...1893
FUEL MIXES INTO ENGINE OIL...1895
WATER MIXES INTO ENGINE OIL (MILKY)...1896
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEAT)...1897
UNUSUAL NOISE IS HEARD...1898
VIBRATION IS EXCESSIVE...1899
AIR CANNOT BE BLED FROM FUEL CIRCUIT...1900
ACTIVE REGENERATION IS DONE FREQUENTLY...1901
ACTIVE REGENERATION TAKES LONG...1903
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION...1905
ADBLUE/DEF CONSUMPTION IS EXCESSIVE...1906
THERE IS AN UNUSUAL SMELL (IRRITATING ODOR)...1908
FOREIGN MATERIAL MIXES INTO ADBLUE/DEF (ADBLUE/DEF LEVEL INCREASES)...1909
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM...1910
OUTLINE OF FAILURE DISPLAY...1910
TROUBLESHOOTING WHEN ERROR MESSAGE [FPS] IS SHOWN...1911
TROUBLESHOOTING FOR AUTOMATIC GREASE PUMP...1912
REPLACE PUMP ELEMENT...1914
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM...1915
REPLACE AUTO-GREASING CONTROLLER...1917
Assembly procedure when disassembled in troubleshooting...1918
50 DISASSEMBLY AND ASSEMBLY...1
CONTENTS...2
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY...7
HOW TO READ THIS MANUAL...7
COATING MATERIALS LIST...9
SPECIAL TOOLS LIST...13
SKETCHES OF SPECIAL TOOLS...37
PREPARATION...52
DRAIN AND ADD COOLANT...52
DRAIN COOLANT...53
ADD COOLANT...55
DRAIN AND ADD HYDRAULIC OIL...57
DRAIN HYDRAULIC OIL...58
ADD HYDRAULIC OIL...59
DRAIN AND ADD FUEL...61
DRAIN FUEL...62
ADD FUEL...62
COLLECT AND REFILL REFRIGERANT...63
COLLECT REFRIGERANT...64
REFILL REFRIGERANT...65
ENGINE AND COOLING SYSTEM...66
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY...66
REMOVE SUPPLY PUMP ASSEMBLY...67
INSTALL SUPPLY PUMP ASSEMBLY...75
REMOVE AND INSTALL INJECTOR ASSEMBLY...85
REMOVE INJECTOR ASSEMBLY...86
INSTALL INJECTOR ASSEMBLY...99
REMOVE AND INSTALL FUEL DOSER ASSEMBLY...113
REMOVE FUEL DOSER ASSEMBLY...114
INSTALL FUEL DOSER ASSEMBLY...117
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY...120
REMOVE CYLINDER HEAD ASSEMBLY...120
INSTALL CYLINDER HEAD ASSEMBLY...142
REMOVE AND INSTALL EGR VALVE ASSEMBLY...167
REMOVE EGR VALVE ASSEMBLY...167
INSTALL EGR VALVE ASSEMBLY...170
REMOVE AND INSTALL EGR COOLER ASSEMBLY...172
REMOVE EGR COOLER ASSEMBLY...172
INSTALL EGR COOLER ASSEMBLY...178
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY...185
REMOVE STARTING MOTOR ASSEMBLY...186
INSTALL STARTING MOTOR ASSEMBLY...189
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT...194
REMOVE AIR CONDITIONER COMPRESSOR BELT...195
INSTALL AIR CONDITIONER COMPRESSOR BELT...197
REMOVE AND INSTALL ALTERNATOR BELT...200
REMOVE ALTERNATOR BELT...201
INSTALL ALTERNATOR BELT...204
REMOVE AND INSTALL AUTOMATIC TENSIONER...207
REMOVE AUTOMATIC TENSIONER...207
INSTALL AUTOMATIC TENSIONER...208
REMOVE AND INSTALL RADIATOR ASSEMBLY...209
REMOVE RADIATOR ASSEMBLY...210
INSTALL RADIATOR ASSEMBLY...215
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY...221
REMOVE COOLING FAN AND FAN MOTOR ASSEMBLY...222
INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY...225
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY...229
REMOVE HYDRAULIC OIL COOLER ASSEMBLY...230
INSTALL HYDRAULIC OIL COOLER ASSEMBLY...234
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY...238
REMOVE AFTERCOOLER ASSEMBLY...239
INSTALL AFTERCOOLER ASSEMBLY...243
REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY...247
REMOVE POWER TRAIN OIL COOLER ASSEMBLY...248
INSTALL POWER TRAIN OIL COOLER ASSEMBLY...256
REMOVE AND INSTALL ENGINE AND TRANSMISSION ASSEMBLY...267
REMOVE ENGINE AND TRANSMISSION ASSEMBLY...269
INSTALL ENGINE AND TRANSMISSION ASSEMBLY...302
DISCONNECT AND CONNECT ENGINE AND TRANSMISSION ASSEMBLY...335
DISCONNECT ENGINE AND TRANSMISSION ASSEMBLY...336
CONNECT ENGINE AND TRANSMISSION ASSEMBLY...339
REMOVE AND INSTALL ENGINE FRONT OIL SEAL...342
REMOVE ENGINE FRONT OIL SEAL...343
INSTALL ENGINE FRONT OIL SEAL...349
REMOVE AND INSTALL ENGINE REAR OIL SEAL...356
REMOVE ENGINE REAR OIL SEAL...357
INSTALL ENGINE REAR OIL SEAL...358
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY...364
REMOVE ENGINE HOOD ASSEMBLY...365
INSTALL ENGINE HOOD ASSEMBLY...375
REMOVE AND INSTALL FUEL TANK ASSEMBLY...385
REMOVE FUEL TANK ASSEMBLY...386
INSTALL FUEL TANK ASSEMBLY...391
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY...397
REMOVE AdBlue/DEF TANK ASSEMBLY...398
INSTALL AdBlue/DEF TANK ASSEMBLY...404
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...408
REMOVE AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...409
INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...410
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR...413
REMOVE AdBlue/DEF TANK SENSOR...414
INSTALL AdBlue/DEF TANK SENSOR...415
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER...422
REMOVE AdBlue/DEF TANK STRAINER...423
INSTALL AdBlue/DEF TANK STRAINER...423
REMOVE AND INSTALL KDPF ASSEMBLY...424
REMOVE KDPF ASSEMBLY...425
INSTALL KDPF ASSEMBLY...432
DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY...439
DISASSEMBLE KDPF ASSEMBLY...440
ASSEMBLE KDPF ASSEMBLY...445
REMOVE AND INSTALL SCR ASSEMBLY...452
REMOVE SCR ASSEMBLY...453
INSTALL SCR ASSEMBLY...455
REMOVE AND INSTALL KDPF AND SCR ASSEMBLY...458
REMOVE KDPF AND SCR ASSEMBLY...459
INSTALL KDPF AND SCR ASSEMBLY...469
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY...479
REMOVE BELLOWS PIPE ASSEMBLY...480
INSTALL BELLOWS PIPE ASSEMBLY...485
REMOVE AND INSTALL KCCV ASSEMBLY...492
REMOVE KCCV ASSEMBLY...493
INSTALL KCCV ASSEMBLY...496
REMOVE AND INSTALL VGT ASSEMBLY...499
REMOVE VGT ASSEMBLY...499
INSTALL VGT ASSEMBLY...507
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE...515
REMOVE AdBlue/DEF MIXING TUBE...516
INSTALL AdBlue/DEF MIXING TUBE...521
REMOVE AND INSTALL AdBlue/DEF INJECTOR...527
REMOVE AdBlue/DEF INJECTOR...528
INSTALL AdBlue/DEF INJECTOR...532
REMOVE AND INSTALL AdBlue/DEF PUMP...536
REMOVE AdBlue/DEF PUMP...537
INSTALL AdBlue/DEF PUMP...541
REMOVE AND INSTALL AdBlue/DEF HOSE...544
REMOVE AdBlue/DEF HOSE...545
INSTALL AdBlue/DEF HOSE...555
REMOVE AND INSTALL AIR CLEANER ASSEMBLY...563
REMOVE AIR CLEANER ASSEMBLY...564
INSTALL AIR CLEANER ASSEMBLY...566
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY...569
REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY...570
INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY...571
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...573
REMOVE AIR CONDITIONER CONDENSER ASSEMBLY...574
INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...577
POWER TRAIN...580
REMOVE AND INSTALL HST MOTOR ASSEMBLY...580
REMOVE HST MOTOR ASSEMBLY...581
INSTALL HST MOTOR ASSEMBLY...586
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY...592
DISASSEMBLE TRANSMISSION ASSEMBLY...594
ASSEMBLE TRANSMISSION ASSEMBLY...627
DISASSEMBLE AND ASSEMBLE TRANSMISSION CLUTCH PACK ASSEMBLY...665
DISASSEMBLE TRANSMISSION CLUTCH PACK ASSEMBLY...665
ASSEMBLE TRANSMISSION CLUTCH PACK ASSEMBLY...684
REMOVE AND INSTALL FRONT AXLE ASSEMBLY...706
REMOVE FRONT AXLE ASSEMBLY...707
INSTALL FRONT AXLE ASSEMBLY...709
REMOVE AND INSTALL REAR AXLE ASSEMBLY...712
REMOVE REAR AXLE ASSEMBLY...713
INSTALL REAR AXLE ASSEMBLY...722
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY...730
DISASSEMBLE AXLE HOUSING ASSEMBLY...732
ASSEMBLE AXLE HOUSING ASSEMBLY...738
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY...747
DISASSEMBLE DIFFERENTIAL ASSEMBLY...749
ASSEMBLE DIFFERENTIAL ASSEMBLY...759
STEERING SYSTEM...779
REMOVE AND INSTALL STEERING VALVE ASSEMBLY...779
REMOVE STEERING VALVE ASSEMBLY...780
INSTALL STEERING VALVE ASSEMBLY...786
REMOVE AND INSTALL ORBITROL VALVE ASSEMBLY...792
REMOVE ORBITROL VALVE ASSEMBLY...793
INSTALL ORBITROL VALVE ASSEMBLY...795
REMOVE AND INSTALL ROTARY VALVE ASSEMBLY...797
REMOVE ROTARY VALVE ASSEMBLY...798
INSTALL ROTARY VALVE ASSEMBLY...803
BRAKE SYSTEM...808
REMOVE AND INSTALL PARKING BRAKE DISC AND PLATE...808
REMOVE PARKING BRAKE DISC AND PLATE...809
INSTALL PARKING BRAKE DISC AND PLATE...813
UNDERCARRIAGE AND FRAME...817
REMOVE AND INSTALL CENTER HINGE PIN...817
REMOVE CENTER HINGE PIN...819
INSTALL CENTER HINGE PIN...826
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...835
REMOVE COUNTERWEIGHT ASSEMBLY...836
INSTALL COUNTERWEIGHT ASSEMBLY...843
REMOVE AND INSTALL FULL-LENGTH FENDER ASSEMBLY...849
REMOVE FULL-LENGTH FENDER ASSEMBLY...850
INSTALL FULL-LENGTH FENDER ASSEMBLY...852
HYDRAULIC SYSTEM...854
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...854
REMOVE HYDRAULIC TANK ASSEMBLY...856
INSTALL HYDRAULIC TANK ASSEMBLY...867
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND POWER TRAIN PUMP ASSEMBLY...878
REMOVE WORK EQUIPMENT PUMP AND POWER TRAIN PUMP ASSEMBLY...879
INSTALL WORK EQUIPMENT PUMP AND POWER TRAIN PUMP ASSEMBLY...883
REMOVE AND INSTALL STEERING PUMP, COOLING FAN PUMP, AND HST CHARGE PUMP ASSEMBLY...888
REMOVE STEERING PUMP, COOLING FAN PUMP, AND HST CHARGE PUMP ASSEMBLY...889
INSTALL STEERING PUMP, COOLING FAN PUMP, AND HST CHARGE PUMP ASSEMBLY...894
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY...899
REMOVE CONTROL VALVE ASSEMBLY...901
INSTALL CONTROL VALVE ASSEMBLY...907
WORK EQUIPMENT...913
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY...913
REMOVE WORK EQUIPMENT ASSEMBLY...914
INSTALL WORK EQUIPMENT ASSEMBLY...922
DISASSEMBLE AND ASSEMBLE STEERING CYLINDER ASSEMBLY...930
DISASSEMBLE STEERING CYLINDER ASSEMBLY...931
ASSEMBLE STEERING CYLINDER ASSEMBLY...932
DISASSEMBLE AND ASSEMBLE LIFT CYLINDER ASSEMBLY...935
DISASSEMBLE LIFT CYLINDER ASSEMBLY...936
ASSEMBLE LIFT CYLINDER ASSEMBLY...938
DISASSEMBLE AND ASSEMBLE BUCKET CYLINDER ASSEMBLY...941
DISASSEMBLE BUCKET CYLINDER ASSEMBLY...942
ASSEMBLE BUCKET CYLINDER ASSEMBLY...944
CAB RELATED PARTS...947
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY...947
REMOVE OPERATOR CAB ASSEMBLY...948
INSTALL OPERATOR CAB ASSEMBLY...964
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...981
REMOVE OPERATOR CAB GLASS (ADHERED GLASS)...982
INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...983
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY...991
REMOVE AIR CONDITIONER UNIT ASSEMBLY...993
INSTALL AIR CONDITIONER UNIT ASSEMBLY...1006
REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY...1020
REMOVE OPERATOR'S SEAT ASSEMBLY...1021
INSTALL OPERATOR'S SEAT ASSEMBLY...1023
REMOVE AND INSTALL SEATBELT...1025
REMOVE SEATBELT...1026
INSTALL SEATBELT...1026
REMOVE AND INSTALL AJSS LEVER SWITCH ASSEMBLY...1028
REMOVE AJSS LEVER SWITCH ASSEMBLY...1029
INSTALL AJSS LEVER SWITCH ASSEMBLY...1032
ELECTRICAL SYSTEM...1036
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...1036
REMOVE ENGINE CONTROLLER ASSEMBLY...1037
INSTALL ENGINE CONTROLLER ASSEMBLY...1041
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY...1045
REMOVE WORK EQUIPMENT CONTROLLER ASSEMBLY...1046
INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY...1049
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY...1052
REMOVE TRANSMISSION CONTROLLER ASSEMBLY...1053
INSTALL TRANSMISSION CONTROLLER ASSEMBLY...1055
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY...1057
REMOVE MONITOR CONTROLLER ASSEMBLY...1058
INSTALL MONITOR CONTROLLER ASSEMBLY...1059
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY...1061
REMOVE MACHINE MONITOR ASSEMBLY...1062
INSTALL MACHINE MONITOR ASSEMBLY...1068
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR...1075
REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR...1076
INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR...1077
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR...1079
REMOVE KCCV CRANKCASE PRESSURE SENSOR...1080
INSTALL KCCV CRANKCASE PRESSURE SENSOR...1081
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR...1083
REMOVE KDPF TEMPERATURE SENSOR...1084
INSTALL KDPF TEMPERATURE SENSOR...1087
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR...1090
REMOVE KDPF DIFFERENTIAL PRESSURE SENSOR...1091
INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR...1094
REMOVE AND INSTALL SCR TEMPERATURE SENSOR...1097
REMOVE SCR TEMPERATURE SENSOR...1098
INSTALL SCR TEMPERATURE SENSOR...1101
REMOVE AND INSTALL AMMONIA SENSOR...1104
REMOVE AMMONIA SENSOR...1105
INSTALL AMMONIA SENSOR...1107
REMOVE AND INSTALL SCR OUTLET NOx SENSOR...1110
REMOVE SCR OUTLET NOx SENSOR...1111
INSTALL SCR OUTLET NOx SENSOR...1113
REMOVE AND INSTALL GATEWAY CONTROLLER ASSEMBLY...1115
REMOVE GATEWAY CONTROLLER ASSEMBLY...1116
INSTALL GATEWAY CONTROLLER ASSEMBLY...1117
60 MAINTENANCE STANDARD...1
CONTENTS...2
ENGINE AND COOLING SYSTEM...3
MAINTENANCE STANDARD OF ENGINE MOUNT...3
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP...4
MAINTENANCE STANDARD OF SERVO VALVE OF BRAKE AND COOLING FAN PUMP...5
MAINTENANCE STANDARD OF COOLING FAN MOTOR...6
POWER TRAIN...8
MAINTENANCE STANDARD OF DRIVE SHAFT...8
MAINTENANCE STANDARD OF TRANSMISSION...9
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE...11
MAINTENANCE STANDARD OF ECMV...13
MAINTENANCE STANDARD OF VALVE ASSEMBLY (MAIN RELIEF, POWER TRAIN OIL COOLER RELIEF)...14
MAINTENANCE STANDARD OF FRONT AXLE...15
MAINTENANCE STANDARD OF REAR AXLE...16
MAINTENANCE STANDARD OF FRONT CONVENTIONAL DIFFERENTIAL...17
MAINTENANCE STANDARD OF REAR CONVENTIONAL DIFFERENTIAL...20
MAINTENANCE STANDARD OF FRONT LIMITED SLIP DIFFERENTIAL...23
MAINTENANCE STANDARD OF REAR LIMITED SLIP DIFFERENTIAL...25
MAINTENANCE STANDARD OF FINAL DRIVE...27
STEERING SYSTEM...30
MAINTENANCE STANDARD OF STEERING COLUMN...30
MAINTENANCE STANDARD OF STEERING PUMP...31
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING PUMP...34
MAINTENANCE STANDARD OF STEERING VALVE...35
MAINTENANCE STANDARD OF STEERING CYLINDER...37
MAINTENANCE STANDARD OF SECONDARY STEERING PUMP...40
BRAKE SYSTEM...41
MAINTENANCE STANDARD OF CHARGE VALVE...41
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR...43
MAINTENANCE STANDARD OF SLACK ADJUSTER...44
MAINTENANCE STANDARD OF FRONT BRAKE...45
MAINTENANCE STANDARD OF REAR BRAKE...47
MAINTENANCE STANDARD OF PARKING BRAKE...49
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE...50
MAINTENANCE STANDARD OF BRAKE COOLING STRAINER...51
UNDERCARRIAGE AND FRAME...52
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN...52
HYDRAULIC SYSTEM...58
MAINTENANCE STANDARD OF HYDRAULIC TANK...58
MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP...59
MAINTENANCE STANDARD OF POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP...60
MAINTENANCE STANDARD OF HST CHARGE PUMP...62
MAINTENANCE STANDARD OF HST CHARGE PUMP AND BRAKE COOLING PUMP...64
MAINTENANCE STANDARD OF CONTROL VALVE...66
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE...75
WORK EQUIPMENT...76
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE...76
MAINTENANCE STANDARD OF BUCKET...80
MAINTENANCE STANDARD OF LIFT CYLINDER...81
MAINTENANCE STANDARD OF BUCKET CYLINDER...82
80 APPENDIX...1
CONTENTS...2
AIR CONDITIONER SYSTEM...4
PRECAUTIONS FOR REFRIGERANT...4
AIR CONDITIONER...5
SPECIFICATIONS OF AIR CONDITIONER...7
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE...8
OUTLINE OF REFRIGERATION CYCLE...9
COMPONENT PARTS OF AIR CONDITIONER SYSTEM...11
AIR CONDITIONER UNIT...11
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT...11
FUNCTION OF AIR CONDITIONER UNIT...12
COMPONENT PARTS OF AIR CONDITIONER UNIT...13
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT...13
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT...13
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT...14
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT...14
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT...14
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT...14
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT...14
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT...15
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...15
FUNCTION OF DUAL PRESSURE SWITCH...16
AIR CONDITIONER CONTROLLER...17
STRUCTURE OF AIR CONDITIONER CONTROLLER...17
COMPRESSOR...18
STRUCTURE OF COMPRESSOR...18
SPECIFICATIONS OF COMPRESSOR...18
FUNCTION OF COMPRESSOR...18
CONDENSER...19
STRUCTURE OF CONDENSER...19
SPECIFICATIONS OF CONDENSER...19
FUNCTION OF CONDENSER...19
RECEIVER DRIER...20
STRUCTURE OF RECEIVER DRIER...20
SPECIFICATIONS OF RECEIVER DRIER...20
FUNCTION OF RECEIVER DRIER...20
SENSORS FOR AIR CONDITIONER SYSTEM...21
FUNCTION OF SUNLIGHT SENSOR...21
FUNCTION OF AMBIENT TEMPERATURE SENSOR...21
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER...22
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER...24
AIR CONDITIONER SYSTEM DIAGRAM...27
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER...28
FUNCTION OF AIR CONDITIONER CONTROLLER...29
LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS...30
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION...35
OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF MACHINE MONITOR...36
CHECK TEMPERATURE CONTROL FUNCTION...38
CHECK TEMPERATURE CONTROL FUNCTION...38
TEST VENT (MODE) CHANGEOVER...40
TEST VENT (MODE) CHANGEOVER...40
TESTING FRESH/RECIRC AIR CHANGEOVER...42
TEST FRESH/RECIRC AIR CHANGEOVER...42
TEST EVAPORATOR TEMPERATURE SENSOR...43
TEST RELAYS...45
TEST RELAYS...45
AIR CONDITIONER TROUBLESHOOTING CHART 1...47
AIR CONDITIONER TROUBLESHOOTING CHART 2...48
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...51
FAILURE CODE [879AKA]...53
FAILURE CODE [879AKB]...55
FAILURE CODE [879BKA]...57
FAILURE CODE [879BKB]...59
FAILURE CODE [879CKA]...61
FAILURE CODE [879CKB]...63
FAILURE CODE [879DKZ]...65
FAILURE CODE [879EMC]...67
FAILURE CODE [879FMC]...70
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)...73
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)...77
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)...81
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER...85
TROUBLESHOOTING USING GAUGE PRESSURE...87
CONNECTION OF SERVICE TOOL...90
METHOD FOR CONNECTING SERVICE TOOL...91
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS...92
HANDLE COMPRESSOR OIL...94
90 CIRCUIT DIAGRAMS...1
CONTENTS...2
HOW TO READ THE CODES FOR ELECTRIC CABLE...3
HYDRAULIC CIRCUIT DIAGRAM...7
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM...7
HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT (1/4)...11
HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT (2/4)...13
HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT (3/4)...15
HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT (4/4)...17
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM...19
HYDRAULIC AUTO-GREASING DIAGRAM...21
ELECTRICAL CIRCUIT DIAGRAM...23
SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM...23
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/11)...27
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/11)...29
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/11)...31
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/11)...33
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/11)...35
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/11)...37
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/11)...39
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/11)...41
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/11)...43
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (10/11)...45
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (11/11)...47
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (AJSS SPECIFICATION) (1/9)...49
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (AJSS SPECIFICATION) (2/9)...51
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (AJSS SPECIFICATION) (3/9)...53
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (AJSS SPECIFICATION) (4/9)...55
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (AJSS SPECIFICATION) (5/9)...57
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (AJSS SPECIFICATION) (6/9)...59
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (AJSS SPECIFICATION) (7/9)...61
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (AJSS SPECIFICATION) (8/9)...63
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (AJSS SPECIFICATION) (9/9)...65
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (STEERING WHEEL SPECIFICATION) (1/10)...67
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (STEERING WHEEL SPECIFICATION) (2/10)...69
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (STEERING WHEEL SPECIFICATION) (3/10)...71
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (STEERING WHEEL SPECIFICATION) (4/10)...73
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (STEERING WHEEL SPECIFICATION) (5/10)...75
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (STEERING WHEEL SPECIFICATION) (6/10)...77
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (STEERING WHEEL SPECIFICATION) (7/10)...79
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (STEERING WHEEL SPECIFICATION) (8/10)...81
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (STEERING WHEEL SPECIFICATION) (9/10)...83
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (STEERING WHEEL SPECIFICATION) (10/10)...85
Komatsu WHEEL LOADER WA475, WA475-E0 Repair Service Manual
