Komatsu Wheel Loaders WA500-Series Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loaders WA500, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loaders WA500 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.
PRODUCT DETAILS:
Total Pages: 35,532 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
COVER...1
00 Index and foreword ...3
Index ...4
Foreword, safety and general information ...21
Important safety notice ...21
How to read the shop manual ...28
Explanation of terms for maintenance standard ...30
Handling equipment of fuel system devices ...32
Handling of intake system parts ...33
Handling of hydraulic equipment ...34
Method of disconnecting and connecting of push-pull type coupler ...36
Handling of electrical equipment ...39
How to read electric wire code ...47
Precautions when performing operation ...50
Practical use of KOMTRAX ...54
Standard tightening torque table ...55
List of abbreviation ...59
Conversion table ...64
01 Specification ...69
Table of contents ...70
Specifications ...71
Specification drawing ...71
Specification ...73
Weight table ...80
Table of fuel, coolant, and lubricants ...82
10 Structure and function ...85
Table of contents ...86
Engine and cooling system ...88
Engine related parts ...88
KVGT ...90
EGR system piping drawing ...96
EGR system circuit diagram ...98
EGR valve ...99
EGR cooler ...101
KCCV layout drawing ...103
KCCV ventilator ...105
KDPF ...107
Engine mount and transmission mount ...111
Joint ...112
Cooling system ...113
Cooling fan pump ...117
Cooling fan motor ...126
Power train ...133
Power train system ...133
Drive shaft ...136
Power train piping drawing ...137
Transmission control ...138
Torque converter ...140
Torque converter regulator valve ...147
Transmission ...149
Transfer ...166
Transmission control valve ...168
Forward and reverse clutch ECMV and gear speed clutch ECMV ...171
Lockup clutch ECMV ...178
Main relief valve, torque converter relief valve, and main flow selector valve ...182
Torque converter oil cooler ...187
Center support ...188
Lubricating oil relief valve ...189
Axle ...190
Differential ...194
Final drive ...204
Steering system ...206
Layout of steering parts ...206
Steering column ...207
Joystick steering lever linkage ...208
Steering pump ...209
Steering control valve ...221
Orbitrol valve ...231
Stop valve ...237
Emergency steering piping diagram ...238
Diverter valve ...239
Emergency steering pump ...243
Brake system ...244
Layout of brake parts ...244
Charge valve ...246
Brake valve ...252
Slack adjuster ...257
Accumulator (for brake) ...260
Brake ...261
Parking brake control ...263
Parking brake ...264
Parking brake solenoid valve ...266
Parking brake emergency release valve ...269
Undercarriage and frame ...270
Axle mount ...270
Center hinge pin ...271
Tire ...273
Hydraulic system ...275
Hydraulic component layout ...275
Work equipment control ...277
Hydraulic tank ...279
Double type gear pump ...282
Work equipment pump ...283
Control valve ...304
CLSS ...313
Hydraulic circuit diagram and names of valves ...317
Accumulator charge valve ...329
Work equipment lock solenoid valve ...333
Accumulator (for PPC circuit) ...334
Accumulator (for ECSS) ...335
Work equipment ...336
Work equipment linkage ...336
Bucket ...337
Bucket positioner and boom positioner ...339
Lubrication of work equipment ...340
Cab and its attachments ...342
ROPS cab ...342
Electrical system ...343
Engine control system ...343
Preheating system ...345
Power mode selector circuit ...347
Engine output limit function ...348
Automatic warm-up function ...349
Parking brake control system ...350
System operating lamp function ...352
Battery disconnect switch function ...354
Backup lamp and brake lamp ...356
Clearance lamp and headlamp ...358
Working lamp ...359
Horn circuit ...360
Wiper and window washer circuit ...361
Transmission controller system ...364
Work equipment control system ...389
Machine monitor system ...409
Rear view monitor system ...433
KOMTRAX system ...436
System component parts ...439
Sensor ...473
20 Standard value tables ...497
Table of contents ...498
Standard service value table ...499
Standard value table for engine ...499
Standard value table for machine ...501
Standard value table for electrical system ...516
30 Testing and adjusting ...531
Table of contents ...532
General information on testing and adjusting ...534
Tools for testing and adjusting ...534
Sketch of tools for testing and adjusting ...539
Engine and cooling system ...541
Testing engine speed ...541
Testing boost pressure ...543
Testing exhaust gas temperature ...545
Testing exhaust gas color ...547
Testing and adjusting valve clearance ...550
Testing compression pressure ...552
Testing blowby pressure ...555
Testing engine oil pressure ...557
Testing EGR valve and KVGT driving oil pressure ...559
Testing fuel pressure ...561
Testing fuel return rate and leakage ...563
Bleeding air from fuel system ...567
Testing fuel circuit for leakage ...569
Handling cylinder cutout mode operation ...570
Handling no injection cranking operation ...571
Testing of KDPF and muffler stack for looseness and damage ...572
Testing of installed condition of cylinder head and manifolds ...573
Testing engine piping for damage and looseness ...574
Replacing and adjusting belt for alternator and air conditioner compressor ...575
Procedures for cleaning fuel doser ...576
Writing compensation values at replacement of injector and engine controller ...579
Power train ...583
Adjusting transmission output speed sensor ...583
Adjusting transmission input speed sensor ...584
Flushing procedure for torque converter and transmission hydraulic circuit ...585
Retrieval of disabled machine due to transmission valve failure ...587
Testing oil leakage from axle final drive ...589
Testing drive shaft for looseness, backlash, and damage ...590
Testing and adjusting power train oil pressure ...591
Steering system ...605
Testing directional lever ...605
Testing steering wheel ...606
Testing work equipment control lever ...608
Testing and adjusting steering circuit oil pressure ...610
Bleeding air from steering cylinder circuit. ...613
Testing and adjusting steering stopper valve ...614
Brake system ...616
Testing brake pedal ...616
Testing and adjusting brake pedal linkage ...617
Adjustment procedure of transmission cut-off proximity switch of left brake pedal ...618
Testing braking performance ...619
Testing and adjusting of accumulator charge pressure ...620
Testing wheel brake oil pressure ...622
Testing lowering of wheel brake pressure ...623
Testing wear of wheel brake disc ...626
Bleeding air from wheel brake circuit ...627
Releasing remaining pressure in brake accumulator circuit ...629
Testing parking brake performance ...630
Testing parking brake oil pressure ...631
Testing wear of parking brake disc ...633
Method of releasing parking brake manually ...634
Hydraulic system ...636
Testing fan speed ...636
Testing fan pump circuit oil pressure ...637
Bleeding air from hydraulic fan circuit ...639
Testing work equipment EPC oil pressure ...641
Testing and adjusting work equipment oil pressure ...643
Bleeding air from work equipment circuit ...649
Releasing remaining pressure from work equipment circuit ...650
Checking of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ...651
Work equipment ...656
Testing and adjusting bucket position detection lever ...656
Testing and adjusting boom position detection lever ...657
Electrical system ...658
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ...658
Special functions of machine monitor ...660
Adjusting rearview camera angle ...753
Handling voltage circuit of engine controller ...754
Handling battery disconnect switch ...755
Testing diodes ...756
Pm clinic ...757
Pm Clinic service ...757
Check sheet ...758
40 Troubleshooting ...765
Table of contents ...766
General information on troubleshooting ...776
Troubleshooting points ...776
Sequence of events in troubleshooting ...778
Check before troubleshooting ...780
Inspection procedure before troubleshooting ...782
Preparation work for troubleshooting of electrical system ...799
Classification and procedures for troubleshooting ...805
Symptom and troubleshooting numbers ...808
Information in troubleshooting table ...811
Connector list and layout ...813
Connector contact identification ...828
T-branch box and T-branch adapter table ...864
Fuse location table ...870
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ...873
Precautions on troubleshooting of machine monitor ...876
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ...878
Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors) ...883
Fabrication of short-circuit connector (for CA1883 and CA3135) ...884
Failure codes table ...885
Troubleshooting by failure code (Display of code) ...900
Failure code [1500L0] Double Engagement of T/M Clutches ...900
Failure code [15B0NX] Transmission Oil Filter Clogging ...901
Failure code [15SAL1] Release Trouble of ECMV (Forward) ...902
Failure code [15SALH] Malfunction of ECMV (Forward) ...904
Failure code [15SBL1] Release Trouble of ECMV (Reverse) ...906
Failure code [15SBLH] Malfunction of ECMV (Reverse) ...908
Failure code [15SEL1] Release Trouble of ECMV (1st clutch) ...910
Failure code [15SELH] Malfunction of ECMV (1st) ...912
Failure code [15SFL1] Release Trouble of ECMV (2nd) ...914
Failure code [15SFLH] Malfunction of ECMV (2nd) ...916
Failure code [15SGL1] Release Trouble of ECMV (3rd) ...918
Failure code [15SGLH] Malfunction of ECMV (3rd) ...920
Failure code [15SHL1] Release Trouble of ECMV (4th) ...922
Failure code [15SHLH] Malfunction of ECMV (4th) ...924
Failure code [2F00MA] Failure of Parking Brake Circuit ...926
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ...929
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ...931
Failure code [879AKA] A/C Inner Sensor Open Circuit ...933
Failure code [879AKB] A/C Inner Sensor Short Circuit ...934
Failure code [879BKA] A/C Outer Sensor Open Circuit ...935
Failure code [879BKB] A/C Outer Sensor Short Circuit ...936
Failure code [879CKA] Ventilating Sensor Open Circuit ...937
Failure code [879CKB] Ventilating Sensor Short Circuit ...938
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ...939
Failure code [879EMC] Ventilation Damper Abnormality ...940
Failure code [879FMC] Air Mix Damper Abnormality ...941
Failure code [989A00] Engine Overrun Prevention Activated ...942
Failure code [989L00] Engine Controller Lock Caution 1 ...943
Failure code [989M00] Engine Controller Lock Caution 2 ...944
Failure code [989N00] Engine Controller Lock Caution 3 ...945
Failure code [A1U0N3] HC Desorb Request 1 ...946
Failure code [A1U0N4] HC Desorb Request 2 ...948
Failure code [AA10NX] Air Cleaner Clogging ...950
Failure code [B@BAZG] Eng Oil Press Low ...952
Failure code [B@BCNS] Eng Water Overheat ...953
Failure code [B@BCZK] Eng Water Level Low ...954
Failure code [B@CENS] T/C Oil Temp. Overheat ...956
Failure code [B@HANS] HYD Oil Temp. Overheat ...957
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ...958
Failure code [CA122] Chg Air Press Sensor High Error ...959
Failure code [CA123] Chg Air Press Sensor Low Error ...961
Failure code [CA131] Throttle Sensor High Error ...963
Failure code [CA132] Throttle Sensor Low Error ...965
Failure code [CA135] Eng Oil Press Sensor High Error ...967
Failure code [CA141] Eng Oil Press Sensor Low Error ...969
Failure code [CA144] Coolant Temp Sens High Error ...971
Failure code [CA145] Coolant Temp Sens Low Error ...973
Failure code [CA153] Chg Air Temp Sensor High Error ...975
Failure code [CA154] Chg Air Temp Sensor Low Error ...977
Failure code [CA187] Sensor 2 Supply Volt Low Error ...979
Failure code [CA221] Ambient Press Sens High Error ...981
Failure code [CA222] Ambient Press Sens Low Error ...983
Failure code [CA227] Sensor 2 Supply Volt High Error ...985
Failure code [CA234] Eng Overspeed ...986
Failure code [CA238] Ne Speed Sensor Supply Volt Error ...987
Failure code [CA239] Ne Speed Sens Supply Volt High Error ...988
Failure code [CA271] IMV/PCV1 Short Error ...989
Failure code [CA272] IMV/PCV1 Open Error ...990
Failure code [CA273] PCV2 Short Error ...991
Failure code [CA274] PCV2 Open Error ...992
Failure code [CA322] Inj #1(L#1) Open/Short Error ...993
Failure code [CA323] Inj #5(L#5) Open/Short Error ...995
Failure code [CA324] Inj #3(L#3) Open/Short Error ...997
Failure code [CA325] Inj #6(L#6) Open/Short Error ...999
Failure code [CA331] Inj #2(L#2) Open/Short Error ...1001
Failure code [CA332] Inj #4(L#4) Open/Short Error ...1003
Failure code [CA343] ECM Critical Internal Failure ...1005
Failure code [CA351] Injectors Drive Circuit Error ...1006
Failure code [CA352] Sensor 1 Supply Volt Low Error ...1007
Failure code [CA356] Mass Air Flow Sensor High Error ...1009
Failure code [CA357] Mass Air Flow Sensor Low Error ...1011
Failure code [CA386] Sensor 1 Supply Volt High Error ...1013
Failure code [CA431] Idle Validation Sw Error ...1014
Failure code [CA432] Idle Validation Process Error ...1017
Failure code [CA441] Battery Voltage Low Error ...1020
Failure code [CA442] Battery Voltage High Error ...1022
Failure code [CA449] Rail Press Very High Error ...1023
Failure code [CA451] Rail Press Sensor High Error ...1024
Failure code [CA452] Rail Press Sensor Low Error ...1026
Failure code [CA515] Rail Press Sens Sup Volt High Error ...1028
Failure code [CA516] Rail Press Sens Sup Volt Low Error ...1030
Failure code [CA553] Rail Press High Error ...1032
Failure code [CA555] Crankcase Press High Error 2 ...1033
Failure code [CA556] Crankcase Press High Error 3 ...1034
Failure code [CA559] Rail Press Low Error ...1035
Failure code [CA595] Turbo Speed High Error 2 ...1039
Failure code [CA687] Turbo Speed Low Error ...1040
Failure code [CA689] Eng Ne Speed Sensor Error ...1042
Failure code [CA691] Intake Air Temp Sens High Error ...1044
Failure code [CA692] Intake Air Temp Sens Low Error ...1046
Failure code [CA697] ECM Internal Temp Sensor High Error ...1048
Failure code [CA698] ECM Int Temp Sensor Low Error ...1049
Failure code [CA731] Eng Bkup Speed Sens Phase Error ...1050
Failure code [CA778] Eng Bkup Speed Sensor Error ...1051
Failure code [CA1117] Persistent Data Lost Error ...1053
Failure code [CA1664] KDOC Malfunction ...1054
Failure code [CA1691] Regeneration Ineffective ...1057
Failure code [CA1695] Sensor 5 Supply Volt High Error ...1060
Failure code [CA1696] Sensor 5 Supply Volt Low Error ...1061
Failure code [CA1843] Crankcase Press Sens High Error ...1063
Failure code [CA1844] Crankcase Press Sens Low Error ...1065
Failure code [CA1879] KDPF Delta P Sensor High Error ...1067
Failure code [CA1881] KDPF Delta P Sensor Low Error ...1069
Failure code [CA1883] KDPF Delta P Sens In Range Error ...1071
Failure code [CA1921] KDPF Soot Load High Error 1 ...1074
Failure code [CA1922] KDPF Soot Load High Error 2 ...1077
Failure code [CA1923] Dosing Fuel Valve 1 High Error ...1082
Failure code [CA1924] Dosing Fuel Valve 1 Low Error ...1084
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ...1087
Failure code [CA1927] Dosing Fuel Press Sens High Error ...1089
Failure code [CA1928] Dosing Fuel Press Sens Low Error ...1091
Failure code [CA1942] Crankcase Press Sens In Range Error ...1093
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ...1094
Failure code [CA1977] Fuel Doser Open/Short Error ...1096
Failure code [CA1993] KDPF Delta Pressure Low Error ...1098
Failure code [CA2185] Throt Sensor Sup Volt High Error ...1101
Failure code [CA2186] Throt Sensor Sup Volt Low Error ...1103
Failure code [CA2249] Rail Press Very Low Error ...1105
Failure code [CA2265] Fuel Feed Pump Open Error ...1106
Failure code [CA2266] Fuel Feed Pump Short Error ...1108
Failure code [CA2271] EGR Valve Pos Sens High Error ...1110
Failure code [CA2272] EGR Valve Pos Sens Low Error ...1112
Failure code [CA2349] EGR Valve Solenoid Open Error ...1114
Failure code [CA2353] EGR Valve Solenoid Short Error ...1116
Failure code [CA2357] EGR Valve Servo Error ...1118
Failure code [CA2381] KVGT Pos Sens High Error ...1119
Failure code [CA2382] KVGT Pos Sens Low Error ...1121
Failure code [CA2383] KVGT Solenoid Open Error ...1123
Failure code [CA2386] KVGT Solenoid Short Error ...1125
Failure code [CA2387] KVGT Servo Error ...1127
Failure code [CA2555] Grid Htr Relay Volt Low Error ...1128
Failure code [CA2556] Grid Htr Relay Volt High Error ...1130
Failure code [CA2637] KDOC Face Plugging ...1132
Failure code [CA2639] Manual Stationary Regeneration Request ...1134
Failure code [CA2732] Dosing Fuel Valve 2 High Error ...1137
Failure code [CA2733] Dosing Fuel Valve 2 Low Error ...1139
Failure code [CA2741] Dosing Fuel Valve Swap Error ...1141
Failure code [CA2765] Inj Trim Data Error ...1143
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error ...1144
Failure code [CA2881] Dosing Fuel Pressure Low Error 1 ...1147
Failure code [CA3133] KDPF Outlet Press Sens High Error ...1152
Failure code [CA3134] KDPF Outlet Press Sens Low Error ...1154
Failure code [CA3135] KDPF Outlet Press Sens In Range Error ...1156
Failure code [CA3167] Fuel Doser Degradation ...1159
Failure code [CA3251] KDOC Inlet Temp High Error ...1162
Failure code [CA3253] KDOC Temp Error - Non Regeneration ...1165
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...1168
Failure code [CA3255] KDPF Temp Error - Non Regeneration ...1171
Failure code [CA3256] KDPF Outlet Temp High Error 1 ...1175
Failure code [CA3311] KDOC Outlet Temp High Error 2 ...1178
Failure code [CA3312] KDPF Outlet Temp High Error 2 ...1181
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ...1184
Failure code [CA3314] KDOC Inlet Temp Sens High Error ...1187
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ...1190
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ...1194
Failure code [CA3317] KDOC Outlet Temp Sens High Error ...1197
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ...1200
Failure code [CA3319] KDPF Outlet Temp Sens High Error ...1203
Failure code [CA3321] KDPF Outlet Temp Sens Low Error ...1206
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ...1208
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ...1211
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ...1213
Failure code [D160KA] Disconnection of Backup Lamp Relay Output ...1215
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output ...1217
Failure code [D160KY] Hot Short of Backup Lamp Relay Output ...1219
Failure code [D191KA] Disconnection of Neutral Output Relay ...1221
Failure code [D191KB] Ground Fault of Neutral Output Relay ...1223
Failure code [D191KY] Hot Short of Neutral Output Relay ...1225
Failure code [D192KA] Disconnection of ECSS Solenoid ...1227
Failure code [D192KB] Ground Fault of ECSS Solenoid ...1229
Failure code [D192KY] Hot Short of ECSS Solenoid ...1231
Failure code [D193KA] Disconnection of J/S Solenoid Cut Relay ...1232
Failure code [D193KB] Ground Fault of J/S Solenoid Cut Relay ...1234
Failure code [D193KY] Hot Short of J/S Solenoid Cut Relay ...1236
Failure code [D193MC] Malfunction of J/S Solenoid Cut Relay ...1238
Failure code [D19JKZ] Personal Code Relay Abnormality ...1240
Failure code [D1E6KA] Disconnection of Parking Brake Relay ...1242
Failure code [D1E6KB] Ground Fault of Parking Brake Relay ...1244
Failure code [D1E6KY] Hot Short of Parking Brake Relay ...1246
Failure code [D5ZHKA] Failure of Key SW C Signal ...1248
Failure code [D5ZHKB] Key SW C Signal Short Circuit ...1250
Failure code [D5ZHKZ] Failure of Key SW C Signal ...1252
Failure code [D5ZHL6] Disconnection of Key SW C ...1254
Failure code [D811MC] KOMTRAX Error ...1256
Failure code [D862KA] GPS Antenna Open Circuit ...1257
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...1258
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...1260
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ...1262
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ...1263
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ...1265
Failure code [DAF0MB] Monitor ROM Abnormality ...1266
Failure code [DAF0MC] Monitor Error ...1267
Failure code [DAF3KK] Controller Power Source Low (MON) ...1268
Failure code [DAF8KB] Camera Power Supply Short Circuit ...1270
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit ...1271
Failure code [DAFGMC] GPS Module Error ...1273
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ...1274
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) ...1276
Failure code [DAFQKR] CAN2 Discon (Monitor) ...1278
Failure code [DAQ0KK] Controller Power Source Low (T/M) ...1279
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ...1282
Failure code [DAQ0MC] T/M Con Error ...1283
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) ...1284
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ...1286
Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay ...1289
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) ...1291
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) ...1292
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ...1294
Failure code [DAQQKR] CAN2 Discon (Transmission Con) ...1296
Failure code [DAQRKR] CAN1 Discon (Transmission Con) ...1297
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ...1298
Failure code [DAZ9KQ] A/C Model Selection Abnormality ...1299
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ...1300
Failure code [DB2QKR] CAN2 Discon (Engine Con) ...1301
Failure code [DB2RKR] CAN1 Discon (Engine Con) ...1306
Failure code [DB90KK] Drop in BBC Controller Main Power Source ...1311
Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) ...1314
Failure code [DB90MC] BBC Error ...1315
Failure code [DB91KA] Disconnection of Key SW ACC (BBC) ...1316
Failure code [DB92KK] Solenoid Power Source Low (BBC) ...1318
Failure code [DB95KX] Failure of 5 V Power Source 1 ...1320
Failure code [DB96KX] Failure of 5 V Power Source 2 ...1324
Failure code [DB99KQ] Inconsistency of Model Selection (BBC) ...1328
Failure code [DB9LKA] Operating Lamp Open Circuit (BBC) ...1329
Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) ...1331
Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) ...1333
Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) ...1334
Failure code [DB9RMA] Inconsistency of Option Selection (BBC) ...1335
Failure code [DBE5KX] Failure of 5V Power Source ...1336
Failure code [DBE6KX] Failure of 24 V Power Source ...1338
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ...1340
Failure code [DDA8KY] Hot Short of Throttle Lock Set SW ...1344
Failure code [DDA9KY] Hot Short of Throttle Lock Resume SW ...1346
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ...1348
Failure code [DDB6L4] Neutral Signal Malfunction ...1350
Failure code [DDD1LD] Failure of Bucket Positioner Set Switch ...1353
Failure code [DDE5KA] Failure of Emergency Steering Signal ...1357
Failure code [DDK3KA] FNR SW Input Signal Disconnection ...1359
Failure code [DDK3KB] FNR SW Input Signal Short Circuit ...1364
Failure code [DDK4KA] J/S FNR Input Signal Disconnection ...1368
Failure code [DDK4KB] J/S FNR Input Signal Short Circuit ...1371
Failure code [DDK5L4] Failure of J/S Shift Up/Down SW ...1373
Failure code [DDK6KA] FNR Lever Input Signal Disconnection ...1375
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ...1378
Failure code [DDNRKY] Hot Short of Work Equipment Lock SW ...1380
Failure code [DDT0L4] Failure of Shift Mode Select SW ...1384
Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal ...1388
Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal ...1392
Failure code [DDW9LD] Ground Fault of Kickdown Switch ...1396
Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW ...1400
Failure code [DF10KA] Disconnection of Shift Lever Input ...1404
Failure code [DF10KB] Ground Fault of Shift Lever Input ...1407
Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor ...1409
Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor ...1411
Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor ...1413
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ...1415
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor ...1416
Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor ...1418
Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor ...1420
Failure code [DH21KA] Failure of Loader Pump Press. Sensor ...1422
Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit ...1424
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit ...1426
Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor ...1428
Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor ...1430
Failure code [DHQ2KX] Out of Range of Main Flow Sel. Valve S. ...1432
Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor ...1434
Failure code [DHT2L6] Failure of T/M Oil Filter Sensor Circuit ...1436
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor ...1437
Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor ...1440
Failure code [DHT8KA] Failure of Steering Pump Press. Sensor ...1443
Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit ...1445
Failure code [DHT8ZG] Steering Oil Pressure Low ...1447
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ...1448
Failure code [DK55KA] Failure of FNR Lever Potentio ...1450
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ...1452
Failure code [DK55L5] Failure of FNR Lever Potentio ...1454
Failure code [DK59KA] Failure of Boom Lever Potentio (Main) ...1455
Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) ...1460
Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree ...1465
Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub) ...1472
Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) ...1478
Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) ...1483
Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) ...1488
Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree ...1493
Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) ...1500
Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) ...1505
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ...1510
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ...1515
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ...1519
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) ...1525
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) ...1530
Failure code [DK5FKA] Failure of J/S Lever Potentio (Main) ...1534
Failure code [DK5FKY] Hot Short of J/S Lever Potentio (Main) ...1537
Failure code [DK5FL8] J/S Lever Potentio (Main & Sub) Disagree ...1540
Failure code [DK5GKA] Failure of J/S Lever Potentio (Sub) ...1544
Failure code [DK5GKY] Hot Short of J/S Lever Potentio (Sub) ...1547
Failure code [DKA0KA] Failure of Boom Angle Sensor ...1550
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit ...1552
Failure code [DKA0L0] Boom Angle Sensor Dislocation ...1554
Failure code [DKA1KA] Failure of Bucket Angle Sensor ...1556
Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit ...1558
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor ...1560
Failure code [DLF1LC] Failure of T/M Input Speed Sensor ...1562
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor ...1564
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ...1566
Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main) ...1568
Failure code [DLT3LC] Failure of Output Speed Sensor (Main) ...1570
Failure code [DPQ1KR] LIN Discon (Switch Panel) ...1572
Failure code [DPQ2KR] LIN Discon (LED Unit) ...1575
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ...1578
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ...1581
Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator ...1583
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ...1587
Failure code [DV00KB] Ground Fault of Buzzer Output ...1591
Failure code [DW2BKA] Disconnection of Main Flow Selector Sol. ...1593
Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol. ...1594
Failure code [DW2BKY] Hot Short of Main Flow Selector Sol. ...1595
Failure code [DW2BL1] Release Trouble of Main Flow Sel. Valve ...1596
Failure code [DW2BLH] Malfunction of Main Flow Selector Valve ...1597
Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) ...1598
Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise) ...1600
Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) ...1602
Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) ...1604
Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) ...1606
Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) ...1608
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ...1610
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) ...1612
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ...1614
Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) ...1616
Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) ...1618
Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) ...1620
Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid ...1622
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. ...1623
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. ...1625
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ...1626
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid ...1628
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ...1630
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ...1632
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ...1636
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ...1640
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ...1644
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ...1648
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ...1652
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. ...1656
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ...1658
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ...1660
Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid ...1662
Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid ...1664
Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid ...1666
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ...1667
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ...1669
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) ...1671
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) ...1673
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) ...1675
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) ...1677
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) ...1679
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) ...1681
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) ...1683
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ...1685
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) ...1686
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) ...1688
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) ...1690
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ...1692
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) ...1694
Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) ...1696
Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward) ...1698
Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) ...1700
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) ...1702
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) ...1704
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) ...1706
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ...1708
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) ...1710
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ...1712
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ...1714
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ...1716
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ...1718
Failure code [DXHLKA] Disconnection of J/S Right EPC Solenoid ...1720
Failure code [DXHLKB] Ground Fault of J/S Right EPC Solenoid ...1722
Failure code [DXHLKY] Hot Short of J/S Right EPC Solenoid ...1724
Failure code [DXHMKA] Disconnection of J/S Left EPC Solenoid ...1726
Failure code [DXHMKB] Ground Fault of J/S Left EPC Solenoid ...1728
Failure code [DXHMKY] Hot Short of J/S Left EPC Solenoid ...1730
Failure code [LA00L3] Failure of Fan Reverse ...1732
Troubleshooting of electrical system (E-mode) ...1733
E-1 Engine does not start (Engine does not crank) ...1733
E-2 Manual preheating system does not work ...1740
E-3 Automatic preheating system does not work ...1743
E-4 While preheating is working, preheating monitor does not light up ...1745
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing ...1747
E-6 LCD unit on machine monitor displays nothing ...1750
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ...1752
E-8 LCD on machine monitor does not display properly ...1754
E-9 Meter unit display on machine monitor is abnormal ...1756
E-10 Night lighting lamp of meter unit on machine monitor is abnormal ...1759
E-11 Caution LED on machine monitor is abnormal ...1762
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ...1764
E-13 Two switches operation of switch panel on machine monitor does not function ...1766
E-14 Switch panel buzzer of machine monitor is abnormal ...1769
E-15 Rearview monitor does not light up or backlight flickers ...1771
E-16 Rearview monitor images are not displayed clearly ...1774
E-17 Rearview monitor brightness cannot be adjusted ...1777
E-18 Night lighting lamp of rearview monitor is abnormal ...1780
E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ...1782
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position ...1783
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light ...1787
E-22 Air cleaner clogging indicator lamp does not light ...1789
E-23 Radiator coolant level caution lamp does not light ...1790
E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil temperature caution lamp does not light ...1792
E-25 Indication of torque converter oil temperature gauge does not increase, or torque converter oil temperature caution lamp does not light ...1794
E-26 Fuel level gauge does not indicate correct level ...1795
E-27 Seat belt caution lamp indication is abnormal ...1797
E-28 Horn does not sound ...1798
E-29 Horn does not stop sounding ...1800
E-30 Alarm buzzer does not sound ...1801
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ...1802
E-32 Kickdown does not work when kickdown switch is turned ON ...1803
E-33 The hold switch does not work when it is pressed ...1805
E-34 Transmission is always shifted to Neutral, or the brake drags when parking brake applies and FR drive is selected ...1807
E-35 Transmission cut-off mode is not selected or not released ...1810
E-36 Transmission cut-off setting cannot be released ...1812
E-37 FNR switch mode is not selected or not released ...1814
E-38 When operating engine mode selector switch, engine mode selector function does not operate properly ...1816
E-39 Flow of loader pump does not increase from the minimum rate ...1818
E-40 ECSS function cannot be selected or cannot be released ...1819
E-41 None of headlamp, clearance lamp, and tail lamp lights ...1821
E-42 Clearance lamp and tail lamp do not light up or go out ...1823
E-43 Both High and Low beams of headlamp do not light up or go out ...1826
E-44 Low beam of headlamp does not light up or go out ...1830
E-45 High beam of headlamp does not light up or go out ...1832
E-46 Front working lamp does not light up or go out ...1834
E-47 Rear working lamp does not light up or go out ...1837
E-48 All of turn signal lamps and hazard lamps do not light up or go out ...1840
E-49 Turn signal lamps do not light up or go out ...1843
E-50 Hazard lamp does not light up or go out ...1846
E-51 Brake lamp does not light up or stays lighted ...1849
E-52 Backup lamp does not light or continues to light ...1852
E-53 Backup buzzer does not sound or continues to sound ...1855
E-54 Front wiper does not operate ...1857
E-55 Rear wiper does not operate ...1860
E-56 Window washer does not operate ...1863
E-57 Fuel feed pump does not operate or stop automatically ...1866
E-58 KOMTRAX system does not operate properly ...1868
Troubleshooting of hydraulic and mechanical system (H-mode) ...1870
Information described in troubleshooting table (H-mode) ...1870
System chart of hydraulic and mechanical systems ...1871
Failure mode and cause table ...1875
H-1 Machine does not start ...1884
H-2 Torque converter lockup clutch is not disengaged (engine stalls) ...1887
H-3 Torque converter lockup clutch is not engaged ...1888
H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift ...1889
H-5 Large shock is made when machine starts or gear is shifted ...1892
H-6 Machine starts or gear speed shifts with long time lag ...1894
H-7 Torque converter oil temperature is high ...1896
H-8 Machine does not turn ...1898
H-9 Turning response is poor ...1902
H-10 Steering wheel is heavy to turn ...1906
H-11 Machine sways or large shocks are made while machine turns ...1907
H-12 Turning radius differs between right and left turns ...1911
H-13 Wheel brakes do not work or are weak ...1912
H-14 Wheel brakes are not released or drag ...1914
H-15 Parking brake does not work or it is weak ...1915
H-16 Parking brake is not released or drags (including emergency release system) ...1916
H-17 Boom does not rise ...1917
H-18 Boom moves slow or boom lacks lifting force ...1919
H-19 Rising boom slows down at certain height ...1921
H-20 Lift cylinders do not serve to hold bucket on ground ...1922
H-21 Hydraulic drift of boom is large ...1923
H-22 Boom moves up and down during operation ...1924
H-23 Bucket does not tilt back ...1925
H-24 Bucket moves slow or bucket lacks tilt-back force ...1927
H-25 Bucket decelerates during tilt-back operation ...1929
H-26 Bucket cylinder does not hold bucket on ground ...1930
H-27 Hydraulic drift of bucket is large ...1931
H-28 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) ...1932
H-29 Boom and bucket control levers do not move smoothly and are heavy to move ...1933
H-30 Operating work equipment causes engine speed to lower significantly or engine to stall ...1934
H-31 Large shocks are made when work equipment starts to move and stops ...1935
H-32 When certain work equipment stalls hydraulically, other work equipment moves ...1937
H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces ...1938
H-34 Fan speed is abnormal (too high or low, or fan does not rotate) ...1939
H-35 Unusual noise is heard from around fan ...1940
Troubleshooting of engine (S-mode) ...1941
Information mentioned in troubleshooting table (S mode) ...1941
S-1 When starting switch is turned to START position, engine is not cranked ...1942
S-2 The engine cranks but exhaust smoke does not come out ...1943
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) ...1944
S-4 Engine startability is poor ...1945
S-5 Engine does not pick-up smoothly ...1948
S-6 Engine stops during operation ...1951
S-7 Engine runs rough or is unstable ...1953
S-8 Engine lacks power ...1954
S-9 KDPF gets clogged in a short time ...1956
S-10 Engine oil consumption is excessive ...1958
S-11 Engine oil becomes contaminated early ...1959
S-12 Fuel consumption is excessive ...1960
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ...1961
S-14 Oil pressure drops ...1962
S-15 Fuel mixes into engine oil ...1963
S-16 Water mixes into engine oil (milky) ...1964
S-17 Coolant temperature rises too high (overheating) ...1965
S-18 Unusual noise is heard ...1966
S-19 Vibration is excessive ...1967
S-20 Air cannot be bled from fuel circuit ...1968
S-21 Active regeneration is executed frequently ...1969
S-22 Active regeneration takes a long time ...1970
S-23 White smoke is exhausted during active regeneration ...1971
50 Disassembly and assembly ...1973
Table of contents ...1974
General information on disassembly and assembly ...1976
How to read this manual ...1976
Coating materials list ...1978
Special tools list ...1982
Sketches of special tools ...1986
Engine and cooling system ...1995
Removal and installation of supply pump assembly ...1995
Removal and installation of injector assembly ...2001
Removal and installation of cylinder head assembly ...2021
Removal and installation of engine hood assembly ...2042
Removal and installation of radiator core assembly ...2046
Removal and installation of aftercooler ...2049
Removal and installation of hydraulic oil cooler ...2052
Removal and installation of power train oil cooler assembly ...2056
Removal and installation of engine assembly ...2058
Removal and installation of engine front oil seal ...2065
Removal and installation of engine rear oil seal ...2068
Removal and installation of cooling fan and fan motor assembly ...2073
Removal and installation of KDPF assembly ...2075
Disassembly and assembly of KDPF assembly ...2078
Removal and installation of KCCV assembly ...2086
Removal and installation of KVGT assembly ...2088
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ...2092
Removal and installation of air cleaner assembly ...2096
Removal and installation of air conditioner compressor assembly ...2098
Removal and installation of air conditioner condenser assembly ...2100
Removal and installation of belt for alternator and air conditioner compressor ...2102
Removal and installation of fuel tank assembly ...2104
Power train ...2106
Removal and installation of power train unit assembly ...2106
Disconnection and connection of power train unit assembly ...2111
Disassembly and assembly of input transfer assembly ...2115
Disassembly and assembly of torque converter assembly ...2121
Disassembly and assembly of transmission assembly ...2134
Disassembly and assembly of transfer and parking brake assembly ...2161
Removal and installation of front differential assembly ...2177
Disassembly and assembly of differential assembly (with LSD) ...2179
Disassembly and assembly of differential assembly (without LSD) ...2193
Removal and installation of front axle assembly ...2204
Removal and installation of rear axle assembly ...2206
Disassembly and assembly of final drive assembly (front and rear) ...2208
Steering system ...2214
Removal and installation of steering valve assembly ...2214
Brake system ...2216
Removal and installation of brake assembly (front and rear) ...2216
Disassembly and assembly of brake assembly (front and rear) ...2218
Disassembly and assembly of slack adjuster assembly ...2224
Disassembly and assembly of brake accumulator charge valve assembly ...2225
Undercarriage and frame ...2226
Removal and installation of center hinge pin ...2226
Removal and installation of large counterweight assembly ...2233
Removal and installation of small counterweight assembly ...2235
Hydraulic system ...2236
Removal and installation of hydraulic tank assembly ...2236
Removal and installation of work equipment pump assembly ...2239
Removal and installation of steering and power train pump assembly ...2241
Removal and installation of cooling fan pump assembly ...2243
Removal and installation of work equipment control valve assembly ...2245
Disassembly and assembly of work equipment control valve assembly ...2248
Removal and installation of diverter valve assembly ...2251
Disassembly and assembly of steering cylinder assembly ...2253
Disassembly and assembly of work equipment cylinder assembly ...2256
Work equipment ...2261
Removal and installation of work equipment assembly ...2261
Cab and its attachments ...2265
Removal and installation of operator's cab assembly (separate cab and floor specification) ...2265
Removal and installation of operator's cab glass (stuck window glass) ...2269
Removal and installation of operator's seat assembly ...2277
Removal and installation of seat belt ...2279
Removal and installation of air conditioner unit assembly ...2280
Electrical system ...2285
Removal and installation of machine monitor assembly ...2285
Removal and installation of work equipment controller assembly ...2286
Removal and installation of rear view monitor assembly ...2288
Removal and installation of engine controller assembly ...2289
Removal and installation of transmission controller assembly ...2291
Removal and installation of monitor controller assembly ...2292
Removal and installation of mass air flow and temperature sensor ...2294
Removal and installation of KOMTRAX terminal assembly ...2295
60 Maintenance standard ...2297
Table of contents ...2298
Engine and cooling system ...2299
Engine mount and transmission mount ...2299
Joint ...2301
Cooling fan pump ...2302
Servo valve ...2304
Cooling fan motor ...2305
Power train ...2307
Drive shaft ...2307
Torque converter ...2308
Torque converter regulator valve ...2312
Transmission ...2313
Transmission control valve ...2320
Forward and reverse clutch ECMV and gear speed clutch ECMV ...2321
Lockup clutch ECMV ...2322
Main relief valve, torque converter relief valve, and main flow selector valve ...2323
Center support ...2325
Lubricating oil relief valve ...2326
Axle ...2327
Differential ...2329
Final drive ...2335
Steering system ...2337
Steering column ...2337
Steering pump ...2338
Steering control valve ...2342
Steering cylinder ...2343
Diverter valve ...2345
Emergency steering pump ...2346
Brake system ...2347
Charge valve ...2347
Brake valve ...2349
Slack adjuster ...2350
Accumulator (for brake) ...2351
Brake ...2352
Parking brake ...2354
Parking brake solenoid valve ...2356
Undercarriage and frame ...2357
Axle mount ...2357
Center hinge pin ...2360
Hydraulic system ...2362
Hydraulic tank ...2362
Double type gear pump ...2363
Work equipment pump ...2365
Control valve ...2367
Accumulator charge valve ...2376
Work equipment ...2377
Work equipment linkage ...2377
Bucket ...2380
Bucket positioner and boom positioner ...2382
Work equipment cylinder ...2383
80 Appendix ...2385
Table of contents ...2386
Air conditioner components ...2387
Precautions for refrigerant ...2387
Air conditioner component ...2388
Configuration and function of refrigeration cycle ...2390
Outline of refrigeration cycle ...2391
Air conditioner unit ...2393
Dual pressure switch ...2398
Air conditioner controller ...2399
Compressor ...2400
Condenser ...2401
Receiver drier ...2402
Sunlight sensor ...2404
Outer temperature sensor (outside air temperature sensor) ...2405
Procedure for testing and troubleshooting ...2406
Circuit diagram and arrangement of connector pins ...2408
Parts and connectors layout ...2410
Testing with self-diagnosis function ...2415
Testing temperature control system ...2418
Testing vent (mode) changeover ...2420
Testing FRESH/RECIRC air changeover ...2422
Check evaporator temperature sensor ...2424
Testing relays ...2426
Troubleshooting chart 1 ...2428
Troubleshooting chart 2 ...2429
Information in troubleshooting table ...2431
Failure code list related to air conditioner ...2432
Failure code [879AKA] A/C Inner Sensor Open Circuit ...2433
Failure code [879AKB] A/C Inner Sensor Short Circuit ...2435
Failure code [879BKA] A/C Outer Sensor Open Circuit ...2437
Failure code [879BKB] A/C Outer Sensor Short Circuit ...2439
Failure code [879CKA] Ventilating Sensor Open Circuit ...2441
Failure code [879CKB] Ventilating Sensor Short Circuit ...2443
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ...2445
Failure code [879EMC] Ventilation Damper Abnormality ...2447
Failure code [879FMC] Air Mix Damper Abnormality ...2450
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) ...2453
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ...2456
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ...2459
A-4 Troubleshooting for FRESH/RECIRC air changeover ...2462
Troubleshooting with gauge pressure ...2464
Connection of service tool ...2467
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ...2469
Handling of compressor oil ...2471
90 Diagrams and drawings ...2473
Table of contents ...2474
Hydraulic circuit diagram ...2475
Symbols in hydraulic circuit diagram ...2475
Power train hydraulic circuit diagram...2479
Brake hydraulic circuit diagram ...2480
Hydraulic circuit diagram...2482
Electric circuit diagram ...2483
Symbols in electric circuit diagram ...2483
Electrical circuit diagram...2487
Electrical circuit diagram of floor...2500
INDEX...2507
