Service manual Komatsu WA380-7 A64001 & Up | CEBM25604

Komatsu WA380-7 A64001 & Up CEBM25604 (Preview)

CEBM025604 WA380-7 S/N A64001 and UP
– CONTENTS
– 00 FOREWORD
— SAFETY
— Safety Notice
—- Important Safety Notice
—- General Precautions
—- Preparations For Work
—- Precautions During Work
— GENERAL
— HOW TO READ THE SHOP MANUAL
— Volumes
— Distribution And Updating
— Filing Method
— Revised Edition Mark
— Revisions
— Symbols
— Unit
— HOISTING INSTRUCTIONS
— Hoisting
— Making Signs
— Precautions
—- Precautions for Sling Work
—- Precautions for Using Mobile Crane
—- Precautions for Using Overhead Hoist Crane
— Selecting Wire Ropes
— HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
— Points to Remember When Handling Electric Equipment
— Points to Remember When Handling Hydraulic Equipment
— PUSH PULL COUPLER
— Type 1
—- Disconnection
—- Connection
— Type 2
—- Disconnection
—- Connection
— Type 3
—- Disconnection
—- Connection
— EXPLANATION OF MAINTENANCE STANDARD TERMS
— HANDLING OF FUEL SYSTEM DEVICES
— HANDLING OF INTAKE SYSTEM PARTS
— STANDARD TIGHTENING TORQUE
— Bolts and Nuts
— Tightening Torque of Hose Nuts
— Tightening Torque of Split Flange Bolts
— Tightening Torque for Flared Nuts
— Tightening Torques for Split Flanged Bolts
— Tightening Torques for O-ring Boss Piping Joints
— Table Of Tightening Torques for O-ring Boss Plugs
— Tightening Torque for Hoses (Taper Seal Type and Face Seal Type)
— Tightening Torque for Face Seal Joints
— For 102, 107, and 114 Engine Series (Bolts and Nuts)
— For 102, 107, and 114 Engine Series (Eye Joints)
— For 102, 107, and 114 Engine Series (Taper Screws)
— ELECTRIC WIRE CODE
— Classification By Thickness
— Classification By Color And Code
— How To Read Electric Wire Code
— PRECAUTIONS FOR OPERATIONS
— Precautions When Carrying Out Removal Work
— Precautions When Carrying Out Installation Work
— Precautions When Completing the Operation
— CONVERSION TABLES
— Method Of Using The Conversion Table
— COATING MATERIALS
— LIST OF ABBREVIATIONS
— List of Abbreviations Used in the Shop Manual
— List of Abbreviations Used in the Circuit Diagrams
– 01 GENERAL
— SPECIFICATIONS
— Dimension Drawing
— Specification Tables
— WEIGHT TABLE
— FUEL, COOLANT, AND LUBRICANTS
– 10 STRUCTURE AND FUNCTION
— ENGINE AND COOLING SYSTEM
— Engine Related Parts
— KVGT
—- Operation
— EGR System Piping Drawing
—- Function
— EGR System Circuit Diagram
— EGR Valve
—- Structure
—- Operation
— EGR Cooler
—- Operation
— KCCV Layout Drawing
—- Operation
— KCCV Ventilator
—- Function
—- Operation
—- CDR Valve
— KDPF
—- Function
—- Types of Regeneration
— Cooling System
—- Specification
— Cooling Fan Pump
—- Specification
—- Function
—- Operation
— Servo Valve
—- Function
—- Operation
— Cooling Fan Motor System
—- Specifications
— Hydraulic Motor
— Suction Valve
—- Function
—- Operation
— Reversible Valve
— Safety Valve
— POWER TRAIN SYSTEM
— Power Train System
— System Diagram
— Drive Shaft System
—- Function
— Power Train Piping System
— Transmission Control
—- Function
— Torque Converter
—- Specification
— Power Transmitting Route
—- Oil Flow
— Transmission
— Forward and Reverse Clutches
—- 1st and 4th Clutches
—- 2nd and 3rd Clutches
—- Structure
—- Operation of Clutch Pack
— Power Transmitting Route
—- Forward 1st
—- Forward 2nd
—- Forward 3rd
—- Forward 4th
—- Reverse 1st
— Transmission Control Valve
—- Function
— Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV
—- ECMV For Gear Speed Clutch
— Lockup Clutch ECMV
—- ECMV for Lockup Clutch
—- Operation
— Main and Torque Converter Relief Valve System
—- Function
—- Operation
— DRIVE AXLE SYSTEM
— Front Axle Assembly
— Rear Axle Assembly
— Front Differential
— Rear Differential
—- Operation
— Limited Slip Differential
—- Operation
— Final Drive
— STEERING SYSTEM
— Layout of Steering Devices
— Steering Column
— Steering Pump
—- Pump Body
—- Specification
—- Operation
—- Servo Valve
—- LS Valve
—- PC Valve
— Steering Valve
—- Operation of Flow Amplifier
—- Operation of Flow Control Spool
—- Operation of Steering Valve
—- Steering Relief Valve
—- Overload Relief Valve
—- Relief Valve
— Orbitrol Valve
— Stop Valve
— Emergency Steering Motor
—- Function
—- Specifications
— Emergency Steering Pump
—- Specification
— BRAKE SYSTEM
— Layout of brake parts
— Charge Valve
— Brake Valve
—- Function
— Accumulator (for Brakes)
—- Function
—- Specifications
— Brakes
—- Front Brake
—- Rear Brake
—- Operation
— Parking Brake System
—- Brake Control
—- Parking Brake Unit
—- Parking Brake Solenoid Valve
—- Emergency Parking Brake Release Valve
— UNDERCARRIAGE AND FRAME
— Axle Mounting and Center Hinge Pin
— Tires
—- Radial Ply Tire
—- Bias Tire
— HYDRAULIC SYSTEM
— Hydraulic Component Layout
— Work Equipment Control Lever System
—- 3-Lever Type
—- Multi-Function Mono-Lever Type
— Hydraulic Tank
—- Specifications
—- Breather
— Double Type Gear Pump
—- Specification
—- Function
— Work Equipment Pump
— Pump Body
—- Function
—- Structure
—- Specification
—- Operation
— Servo Valve
—- LS Valve
—- PC Valve
— Control Valve
—- Structure
— CLSS
—- Outline of CLSS
— Features
—- Structure
—- Basic Principle
—- Pressure Compensation Control
— Function and Operation of Each Valve
—- Hydraulic Circuit Diagram of Valves
—- Unload Valve
—- Work Equipment Valve (Supply of LS Pressure)
—- LS Bypass Plug
—- Pressure Compensation Valve
—- Boom Regeneration Circuit
—- Variable Back Pressure Valve
—- ECSS Control Valve
—- Accumulator Charge Valve
—- Stabilizer Valve
—- Work Equipment Lock Solenoid Valve
— Accumulator (for PPC Circuit)
—- Function
—- Specifications
— Accumulator (for ECSS)
— WORK EQUIPMENT
— Work Equipment Linkage
— Bucket
— Bucket Positioner and Boom Positioner
— CAB AND ITS ATTACHMENTS
— ROPS Cab
— ELECTRICAL SYSTEM
— Engine Control System
—- Function
—- Operation
— Preheating System
—- Automatic Preheating System
—- Manual Preheating System
— Engine Power Mode Selector Circuit
—- Function
—- Operation
— Engine Output Limit Function
— Automatic Warm-up Function
— Parking Brake Control System
—- Operation
— System Operating Lamp Function
—- Function
— Battery Disconnect Switch Function
—- Function
— Transmission Controller System
—- Transmission Controller System Diagram
—- Transmission Gear Shift Control Function
—- Transmission Protection Function
—- Engine Control Function
—- ECSS Function
—- Directional Switch Control Function
—- Auto Idle Stop Function
—- Real-time Monitoring Function Of Transmission Controller
—- Transmission Controller Self-Diagnosis Function
— Work Equipment Control System
—- Work Equipment Control System Diagram
—- Work Equipment Control Function
—- Work Equipment Neutral Lock Function
—- Neutral Position and Work Equipment Speed
—- Bucket Priority Control
—- Boom Stop Modulation
—- Adjustment of Lever Detent Position and Work Equipment Starting Current
—- Swash Plate Control Function of Work Equipment Pump and Steering Pump
—- Overheat Prevention Function of Work Equipment Controller
—- Remote Positioner Function
—- Semi Auto-Digging Function
—- Electric Emergency Steering Function
—- Real-Time Monitoring Function of Work Equipment Controller
—- Self-Diagnosis Function of Work Equipment Controller
— Machine Monitor System
—- Function
—- Details of Monitor Controller Network Signals
—- Machine Monitor
—- Switch Panel
—- Rear View Monitor System
—- Rear View Monitor
—- Rear View Camera
— KOMTRAX System
—- KOMTRAX Terminal
—- System Component Parts
—- Work Equipment Controller
—- Transmission Controller
—- Machine Controller
—- Work Equipment Electric Lever
—- Throttle Position Sensor
—- Combination Switch
—- Kickdown Switch
—- Hold Switch
—- CAN Terminating Resistor
—- Specifications
—- Engine Oil Pressure Switch
—- Specifications
—- Front Brake Oil Pressure Switch
—- Specification
—- Rear Brake Oil Pressure Switch
—- Specification
—- Stop Lamp Oil Pressure Switch
—- Specification
—- Parking Brake Oil Pressure Switch
—- Specification
— SENSORS
— Ambient Pressure Sensor
—- Function
— Coolant Temperature Sensor
—- Function
— Ne (Crankshaft) Speed Sensor
— Bkup (Camshaft) Speed Sensor
—- Function
— Common Rail Pressure Sensor
—- Function
— Exhaust Manifold Pressure Sensor
—- Function
— EGR Orifice Temperature Sensor
— EGR Valve Lift Sensor
—- Function
— KVGT Speed Sensor
—- Function
— KVGT Position Sensor
—- Function
—- Output characteristics
— Mass Air Flow and Temperature Sensor
—- Function
— KDPF Differential Pressure and Outlet Pressure Sensor
—- Function
— KDOC Inlet Temperature Sensor
—- Function
— KDOC Outlet Temperature Sensor
—- Function
— KDPF Outlet Temperature Sensor
—- Function
— Crankcase Pressure Sensor
—- Function
— Engine Oil Level Sensor
—- Function
— Transmission Input Speed Sensor
—- Function
— Transmission Output Shaft Speed Sensor
—- Function
— Cooling Fan Speed Sensor
—- Function
— Torque Converter Oil Temperature Sensor
—- Function
— Transmission Oil Temperature Sensor
—- Function
— Hydraulic Oil Temperature Sensor
—- Function
— Brake Oil Temperature Sensor
—- Function
— Transmission Inlet Pressure Sensor
—- Function
—- Output characteristics
— Transmission Outlet Pressure Sensor
—- Function
—- Output characteristics
— Oil Pressure Sensor of Work Equipment Pump
—- Function
—- Output characteristics
— Steering Pump Oil Pressure Sensor
—- Function
—- Output characteristics
— Emergency Steering Pump Pressure Sensor
—- Function
—- Output characteristics
— Boom Cylinder Bottom Oil Pressure Sensor
—- Function
—- Output characteristics
— Transmission Cut-off Oil Pressure Sensor
—- Function
—- Output characteristics
— Coolant Level Sensor
—- Function
— Fuel Level Sensor
—- Function
— Air Cleaner Clogging Sensor
—- Function
— Water-in-Fuel Sensor
—- Function
— Boom Potentiometer
—- Function
—- Output characteristics
— Bucket Potentiometer Sensor
—- Function
—- Output characteristics
— QUICK COUPLER
— Quick Coupler Switch
— Quick Coupler Solenoid Valve
— Outline
– 20 STANDARD VALUE TABLES
— STANDARD VALUE TABLES
— Service Value For Engine
— Service Values For Chassis
—- Directional Levers
—- Gear Speed Switch
—- Work Equipment Levers
—- Multi-Function Mono-Lever
—- Steering Wheel
—- Frame
—- Accelerator Pedal
—- Brake Pedal
—- Tires
—- Engine Speed
—- Transmission and Torque Converter
—- Steering
—- Accumulator
—- Power Train
—- Wheel Brake
—- Parking Brake
—- PPC
—- Work Equipment
—- Hydraulic Fan
— Machine Posture
– 30 TESTING AND ADJUSTING
— TOOLS
— Tools for Testing, Adjusting, and Troubleshooting
— Sketch of Tools for Testing and Adjusting
— ENGINE AND COOLING SYSTEM
— Measuring Engine Speed
—- Measurement Conditions
—- Testing
— Measuring Boost Pressure
—- Measuring With Machine Monitor
—- Measuring by Use of Testing Tools
— Testing Exhaust Gas Temperatures
—- Testing
— Testing Exhaust Gas Color
—- Testing
— Testing and Adjusting Valve Clearance
—- Testing
—- Adjusting
— Measuring Compression Pressure
—- Testing
— Measuring Blow-By Pressure
— Measuring Engine Oil Pressure
— Measuring EGR Valve and KVGT Oil Pressure
—- Testing
— Testing Fuel Pressure
—- Testing
—- Testing Low-Pressure Circuit (Pressure Difference)
—- Testing Return Circuit
—- Testing Negative-Pressure Circuit
— Measuring Fuel Delivery, Return and Leakage
—- Testing
—- Testing Supply Pump Return Rate
—- Testing Leakage from Pressure Limiter
—- Testing Fuel Return Rate from Injector
—- Bleeding Air from Fuel System
— Checking Fuel Circuit for Leakage
— Handling Cylinder Cut-Out Mode Operation
— Handling No-Injection Cranking Operation
—- Check of KDPF and Muffler Stack for Looseness and Damage
—- Check of Installed Condition of Cylinder Head and Manifolds
—- Checking Engine Piping for Damage and Looseness
—- Testing and Adjusting Air Conditioner Compressor Belt Tension
—- Replacing Alternator Belt
— POWER TRAIN SYSTEM
— Adjusting Transmission Output Speed Sensor
—- Adjustment
— Adjusting Transmission Input Speed Sensor
—- Adjustment
— Flushing Procedure for Torque Converter and Transmission Hydraulic Circuit
—- Flushing Procedures
— Retrieval of Disabled Machine Due to Transmission Valve Failure
—- How to Move
—- Checking Oil Leakage from Axle Final Drive
—- Checking Drive Shaft for Looseness, Play, and Damage
— Testing and Adjusting Power Train Oil Pressure
—- Testing
—- Adjustment
— STEERING SYSTEM
— Checking Directional Lever
—- Testing
— Testing Steering Wheel
—- Testing
— Testing Work Equipment Control Lever
—- Testing
— Testing and Adjusting Steering Circuit Pressure
—- Testing
—- Adjustment
— Bleeding Air from Steering Cylinder Circuit
—- Bleeding Air
— Testing and Adjusting Steering Stopper Valve
—- Testing
—- Adjustment
— BRAKE SYSTEM
— Testing Brake Pedal
—- Testing
— Testing and Adjusting Brake Pedal Linkage
—- Testing
—- Adjustment
— Testing Braking Performance
—- Testing
— Testing and Adjusting Accumulator Charge Pressure
—- Testing
—- Adjusting
— Testing Wheel Brake Oil Pressure
—- Testing
— Measuring Lowering of Wheel Brake Pressure
—- Testing
—- Brake Test Kit
— Measuring Wear of Wheel Brake Disc
—- Testing
— Bleeding Air From Wheel Brake Circuit
—- Bleeding Air
— Releasing Remaining Pressure in Brake Accumulator Circuit
—- Releasing Remaining Pressure
— Testing Parking Brake Performance
—- Testing
— Testing Parking Brake Oil Pressure
—- Testing
— Testing Wear of Parking Brake Disc
—- Testing
— Method of Releasing Parking Brake Manually
—- How to Release
— HYDRAULIC SYSTEM
— Checking Fan Speed
—- Testing
— Measuring Fan Pump Circuit Oil Pressure
—- Testing
— Bleeding Air from Hydraulic Fan Circuit
—- Bleeding Air
— Testing and Adjusting Work Equipment PPC Oil Pressure
—- Testing
—- Adjustment
— Testing and Adjusting Work Equipment Oil Pressure
—- Preparation
—- Testing
— Bleeding Air from Work Equipment Circuit
—- Bleeding Air from Work Equipment Pump (Piston Pump)
—- Bleeding Air from Cylinder
— Releasing Remaining Pressure from Work Equipment Circuit
—- Releasing Remaining Pressure Between Each Hydraulic Cylinder and Control Valve
—- Releasing Remaining Pressure In ECSS Circuit
— Checking of ECSS Accumulator Nitrogen Gas Pressure and Procedure for Charging Accumulator with Nitrogen Gas
—- Testing Nitrogen Gas Pressure in Accumulator
— Procedure for Charging Accumulator with Nitrogen Gas
— WORK EQUIPMENT
— Testing and Adjusting Bucket Position Detection Lever
—- Testing
—- Adjustment
— Testing and Adjusting Boom Position Detection Lever
—- Testing
—- Adjustment
— ELECTRICAL SYSTEM
— Adjusting Replaced, Reassembled or Added Sensor, Controller, Etc. with Machine Monitor
— Special Functions of Machine Monitor
—- Ordinary Functions and Special Functions of Machine Monitor
—- Operator Mode (outline)
—- Service Mode
— Angle Adjustment of Rear View Camera
—- Adjustment
—- Handling Voltage Circuit of Engine Controller
— Handling Battery Disconnect Switch
— Testing Diodes
—- Testing
— PM-CLINIC INSPECTION TABLE
— Check Sheet
– 40 TROUBLESHOOTING
— POINTS TO REMEMBER WHEN TROUBLESHOOTING
— PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
— Precautions when Handling Electrical Equipment
— Handling Electronic Control Unit
— Points to Remember when Troubleshooting Electrical Circuits
— ELECTRIC WIRE CODE
— Classification by Thickness
— Classification by Color and Code
— How to Read Electric Wire Code
—- Type, Symbol, and Material
—- Dimensions
— HANDLING HYDRAULIC EQUIPMENT
— CHECKS BEFORE TROUBLESHOOTING
— Testing Procedure Before Troubleshooting
—- Walk-Around Check
— Categories and Method of Using Troubleshooting Charts
— Information Mentioned in Troubleshooting Table
— Connector List
— Layout of Connectors (1/7)
— Layout of Connectors (2/7)
— Layout of Connectors (3/7)
— Layout of Connectors (4/7)
— Layout of Connectors (5/7)
— Layout of Connectors (6/7)
— Layout of Connectors (7/7)
— Diagnostic Procedure for Wiring Harness Open Circuit of Pressure Sensor System
— Fuse Location Table
— Precautions for Cleaning and Replacing KDPF (KCSF, KDOC)
— Dummy Temperature Sensor (for KDOC and KDPF Temperature Sensors)
— Short-Circuit Connector (for CA1883 and CA3135)
— Precautions on Troubleshooting of Machine Monitor
— Processing Procedure of Harness Checker for Troubleshooting of Machine Monitor LCD Unit
— TROUBLESHOOTING BY FAILURE CODE
— Failure Code Table
— FAILURE CODES
— [1500L0] Double Engagement of T/M Clutches
— [15SAL1] Release Trouble of ECMV (Forward)
— [15SALH] Malfunction of ECMV (Forward)
— [15SBL1] Release Trouble of ECMV (Release)
— [15BLH] Malfunction of ECMV (Reverse)
— [15SEL1] Release Trouble of ECMV (1st)
— [15SELH] Malfunction of ECMV (1st)
— [15SFL1] Release Trouble of ECMV (2nd)
— [15SFLH] Malfunction of ECMV (2nd)
— [15SGL1] Release Trouble of ECMV (3rd)
— [15SGLH] Malfunction of ECMV (3rd)
— [15SHL1] Release Trouble of ECMV (4th)
— [15SHLH] Malfunction of ECMV (4th)
— [2F00MA] Failure of Parking Brake Circuit
— [2G42ZG] Accumulator Oil Pressure Low (Front)
— [2G43ZG] Accumulator Oil Pressure Low (Rear)
— [879AKA] A/C Inner Sensor Open Circuit
— [879AKB] A/C Inner Sensor Short Circuit
— [879BKA] A/C Outer Sensor Open Circuit
— [879BKB] A/C Outer Sensor Short Circuit
— [879CKA] Ventilating Sensor Open Circuit
— [879CKB] Ventilating Sensor Short Circuit
— [879DKZ] Sunlight Sensor Open or Short Circuit
— [879EMC] Ventilation Damper Abnormality
— [879FMC] Air Mix Damper Abnormality
— [989A00] Engine Overrun Protection Activated
— [989L00] Engine Controller Lock Caution 1
— [989M00] Engine Controller Lock Caution 2
— [989N00] Engine Controller Lock Caution 3
— [A1U0N3] HC Desorb Request 1
— [A1U0N4] HC Desorb Request 2
— [AA10NX] Air Cleaner Clogging
— [B@BAZG] Eng Oil Press Low
— [B@BAZK] Eng Oil Level Low
— [B@BCNS] Eng Water Overheat
— [B@BCZK] Eng Water Level Low
— [B@CENS] T/C Oil Temp. Overheat
— [B@HANS] HYD Oil Temp. Overheat
— [CA115] Eng Ne and Bkup Speed Sens Error
— [CA122] Chg Air Press Sensor High Error
— [CA123] Chg Air Press Sensor Low Error
— [CA131] Throttle Sensor High Error
— [CA132] Throttle Sensor Low Error
— [CA144] Coolant Temp Sens High Error
— [CA145] Coolant Temp Sens Low Error
— [CA153] Chg Air Temp Sensor High Error
— [CA154] Chg Air Temp Sensor High Error
— [CA187] Sensor 2 Supply Volt Low Error
— [CA221] Ambient Press Sensor High Error
— [CA222] Ambient Press Sensor Low Error
— [CA227] Sensor 2 Supply Volt High Error
— [CA234] Eng Overspeed
— [CA238] Ne Speed Sensor Supply Volt Error
— [CA239] Ne Speed Sens Supply Volt High Error
— [CA271] IMV/PCV1 Short Error
— [CA272] IMV/PCV1 Open Error
— [CA295] Ambient Press Sens In Range Error
— [CA322] Inj #1 (L#1) Open/Short Error
— [CA323] Inj #5 (L#5) Open/Short Error
— [CA324] Inj #3 (L#3) Open/Short Error
— [CA325] Inj #6 (L#6) Open/Short Error
— [CA331] Inj #2 (L#2) Open/Short Error
— [CA332] Inj #4 (L#4) Open/Short Error
— [CA343] ECM Critical Internal Failure
— [CA351] Injectors Drive Circuit Error
— [CA352] Sensor 1 Supply Volt Low Error
— [CA356] Mass Air Flow Sensor High Error
— [CA357] Mass Air Flow Sensor Low Error
— [CA386] Sensor 1 Supply Volt High Error
— [CA428] Water in Fuel Sensor High Error
— [CA429] Water in Fuel Sensor Low Error
— [CA431] Idle Validation Switch Error
— [CA432] Idle Validation Process Error
— [CA435] Eng Oil Press Sw Error
— [CA441] Battery Voltage Low Error
— [CA442] Battery Voltage High Error
— [CA449] Rail Press Very High Error
— [CA451] Rail Press Sensor High Error
— [CA452] Rail Press Sensor Low Error
— [CA488] Chg Air Temp High Torque Derate
— [CA515] Rail Press Sens Sup Volt High Error
— [CA516] Rail Press Sens Sup Volt Low Error
— [CA553] Rail Press High Error
— [CA555] Crankcase Press High Error 1
— [CA556] Crankcase Press High Error 2
— [CA559] Rail Press Low Error
— [CA595] Turbo Speed High Error 2
— [CA687] Turbo Speed Low Error
— [CA689] Eng Ne Speed Sensor Error
— [CA691] Intake Air Temp Sens High Error
— [CA692] Intake Air Temp Sens Low Error
— [CA697] ECM Int Temp Sensor High Error
— [CA698] ECM Int Temp Sensor Low Error
— [CA731] Eng Bkup Speed Sens Phase Error
— [CA778] Eng Bkup Speed Sensor Error
— [CA1117] Persistent Data Lost Error
— [CA1664] KDOC Malfunction
— [CA1691] Regeneration Ineffective
— [CA1695] Sensor 5 Supply Volt High Error
— [CA1696] Sensor 5 Supply Volt Low Error
— [CA1843] Crankcase Press Sens High Error
— [CA1844] Crankcase Press Sens Low Error
— [CA1879] KDPF Delta P Sensor High Error
— [CA1881] KDPF Delta P Sensor Low Error
— [CA1883] KDPF Delta P Sens In Range Error
— [CA1921] KDPF Soot Load High Error 1
— [CA1922] KDPF Soot Load High Error 2
— [CA1942] Crankcase Press Sens In Range Error
— [CA1993] KDPF Delta Pressure Low Error
— [CA2185] Throt Sensor Sup Volt High Error
— [CA2186] Throt Sensor Sup Volt Low Error
— [CA2249] Rail Press Very Low Error
— [CA2271] EGR Valve Pos Sens High Error
— [CA2272] EGR Valve Pos Sens Low Error
— [CA2288] Turbo Speed High Error 1
— [CA2311] IMV Solenoid Error
— [CA2349] EGR Valve Solenoid Open Error
— [CA2353] EGR Valve Solenoid Short Error
— [CA2357] EGR Differential Pressure
— [CA2373] Exh Manifold Press. Sens High Error
— [CA2374] Exhaust Manifold Press Sens Low Error
— [CA2375] EGR Orifice Temp Sens High Error
— [CA2376] EGR Orifice Temp Sens Low Error
— [CA2381] KVGT Pos Sens High Error
— [CA2382] KVGT Pos Sens Low Error
— [CA2383] KVGT Solenoid Open Error
— [CA2386] KVGT Solenoid Short Error
— [CA2387] KVGT Servo Error
— [CA2554] Exh Manifold Press Sens In Range Error
— [CA2555] Grid Htr Relay Volt Low Error
— [CA2556] Grid Htr Relay Volt High Error
— [CA2637] KDOC Face Plugging
— [CA2639] Manual Stationary Regeneration Request
— [CA2961] EGR Orifice Temp High Error 1
— [CA2973] Chg Air Press Sensor In Range Error
— [CA3133] KDPF Outlet Press Sens High Error
— [CA3134] KDPF Outlet Press Sens Low Error
— [CA3135] KDPF Outlet Press Sens In Range Error
— [CA3251] KDOC Inlet Temp High Error
— [CA3253] KDOC Temp Error – Non Regeneration
— [CA3254] KDOC Outlet Temp High Error 1
— [CA3255] KDPF Temp Error – Non Regeneration
— [CA3256] KDPF Outlet Temp High Error 1
— [CA3311] KDOC Outlet Temp High Error 2
— [CA3312] KDPF Outlet Temp High Error 2
— [CA3313] KDOC Inlet Temp Sensor Low Error
— [CA3314] KDOC Inlet Temp Sens High Error
— [CA3315] KDOC Inlet Temp Sens In Range Error
— [CA3316] KDOC Outlet Temp Sens Low Error
— [CA3317] KDOC Outlet Temp Sens High Error
— [CA3318] KDOC Inlet Temp Sens In Range Error
— [CA3319] KDPF Outlet Temp Sens High Error
— [CA3321] KDPF Outlet Temp Sens Low Error
— [CA3322] KDPF Outlet Temp Sens In Range Error
— [CA3419] Mass Air Flow Sensor Sup Volt High Error
— [CA3421] Mass Air Flow Sensor Sup Volt Low Error
— [CA3741] Rail Press Valve Trip Error
— [D150KA] Disconnection of Emergency Steering Relay
— [D150KB] Ground Fault of Emergency Steering Relay
— [D150KY] Hot Short of Emergency Steering Relay
— [D160KA] Disconnection of Back-Up Lamp Relay Output
— [D160KB] Ground Fault of Back-Up Lamp Relay Output
— [D160KY] Hot Short of Back-Up Lamp Relay Output
— [D191KA] Disconnection of Neutral Output Relay
— [D191KB] Ground Fault of Neutral Output Relay
— [D191KY] Hot Short of Neutral Output Relay
— [D192KA] Disconnection of ECSS Solenoid
— [D192KB] Ground Fault of ECSS Solenoid
— [D192KY] Hot Short of ECSS Solenoid
— [D19JKZ] Personal Code Relay Abnormality
— [D1E6KA] Disconnection of Parking Brake Relay
— [D1E6KB] Ground Fault of Parking Brake Relay
— [D1E6KY] Hot Short of Parking Brake Relay
— [D5ZHKA] Failure of Key SW C Signal
— [D5ZHKB] Key SW C Signal Short Circuit
— [D5ZHKZ] Failure of Key SW C Signal
— [D5ZHL6] Disconnection of Key SW C
— [D811MC] KOMTRAX Error
— [D862KA] GPS Antenna Open Circuit
— [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
— [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)
— [D8AQK4] CAN2 Discon (KOMTRAX) 2
— [D8AQKR] CAN2 Discon (KOMTRAX)
— [DAF0KT] Abnormality of Non-volatile Memory (MON)
— [DAF0MB] Monitor ROM Abnormality
— [DAF0MC] Monitor Error
— [DAF3KK] Controller Power Source Low (MON)
— [DAF8KB] Camera Power Supply Short Circuit
— [DAFDKB] Monitor 12 V Power Output Short Circuit
— [DAFGMC] GPS Module Error
— [DAFLKA] Operating Lamp Open Circuit (MON)
— [DAFLKB] Operating Lamp Short Circuit (MON)
— [DAFQKR] CAN2 Discon (Monitor)
— [DAQ0KK] Controller Power Source Low (T/M)
— [DAQ0KT] Abnormality of Non-volatile Memory (T/M)
— [DAQ0MC] T/M Con Error
— [DAQ1KA] Disconnection of Key SWACC (T/M)
— [DAQ2KK] Solenoid Power Source Low (T/M)
— [DAQ4KB] Ground Fault of Sol. Self-Holding Relay (TM)
— [DAQ9KQ] Inconsistency of Model Selection (T/M)
— [DAQLKA] Operating Lamp Open Circuit (T/M)
— [DAQLKB] Operating Lamp Short Circuit (T/M)
— [DAQQKR] CAN2 Discon (Transmission Con)
— [DAQRKR] CAN1 Discon (Transmission Con)
— [DAQRMA] Inconsistency of Option Selection (T/M)
— [DAZ9KQ] A/C Model Selection Abnormality
— [DAZQKR] CAN2 Discon (Aircon ECU)
— [DB2QKR] CAN2 Discon (Engine Con)
— [DB2RKR] CAN1 Discon (Engine Con)
— [DB90KK] Drop in BBC Controller Main Power Source
— [DB90KT] Abnormality of Non-Volatile Memory (BBC)
— [DB90MC] BBC Error
— [DB91KA] Disconnection of Key SW ACC (BBC)
— [DB92KK] Solenoid Power Source Low (BBC)
— [DB95KX] Failure of 5 V Power Source 1
— [DB96KX] Failure of 5 V Power Source 2
— [DB99KQ] Inconsistency of Model Selection (BBC)
— [DB9LKA] Operating Lamp Open Circuit (BBC)
— [DB9LKB] Operating Lamp Short Circuit (BBC)
— [DB9QKR] CAN2 Discon (Bucket Boom Con)
— [DB9RKR] CAN1 Discon (Bucket Boom Con)
— [DB9RMA] Inconsistency of Option Selection (BBC)
— [DBE5KX] Failure of 5 V Power Source
— [DBE6KX] Failure of 24 V Power Source
— [DD1ALD] Ground Fault of Remote Positioner Set SW
— [DDAAL6] Disconnection of Secondary Switch ENG Stop SW
— [DDB6L4] Neutral Signal Malfunction
— [DDD1LD] Failure of Bucket Positioner Set Switch
— [DDK3KA] FNR SW Input Signal Disconnection
— [DDK3KB] FNR SW Input Signal Short Circuit
— [DDK6KA] FNR Lever Input Signal Disconnection
— [DDK6KB] FNR Lever Input Signal Short Circuit
— [DDNRKY] Hot Short of Work Equipment Lock SW
— [DDT0L4] Failure of Shift Mode Select SW
— [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal
— [DDT9LD] Ground Fault of T/M Cut Off Set SW Signal
— [DDW9LD] Ground Fault of Kick-Down Switch
— [DDWLLD] Ground Fault of T/M Shift Hold SW
— [DF10KA] Disconnection of Shift Lever Input
— [DF10KB] Ground Fault of Shift Lever Input
— [DGF1KA] Disconnection of T/M Oil Temp Sensor
— [DGF1KB] Ground Fault of T/M Oil Temp. Sensor
— [DGH2KX] Out of Range of HYD Oil Temp. Sensor
— [DGR2KB] Ground Fault of Brake Oil Temp. Sensor
— [DGR2KZ] Failure of Brake Oil Temp. Sensor
— [DGT1KA] Disconnection of T/C Oil Temp. Sensor
— [DGT1KB] Ground Fault of T/C Oil Temp. Sensor
— [DH21KA] Failure of Loader Pump Press. Sensor
— [DH21KB] Loader Pump Press. Sensor Short Circuit
— [DHA4KA] Failure of Air Cleaner Sensor Circuit
— [DHPCKX] Out of Range of Boom Bottom Press. Sensor
— [DHPDKX] Out of Range of Boom Head Press. Sensor
— [DHT1KX] Out of Range of T/M Cut Off Press. Sensor
— [DHT5KX] Out of Range of T/C Input Pressure Sensor
— [DHT7KX] Out of Range of T/C Output Pressure Sensor
— [DHT8KA] Failure of Steering Pump Press. Sensor
— [DHT8KB] Steering Pump Press. Sensor Short Circuit
— [DHT8ZG] Steering Oil Pressure Low
— [DHUDKA] Failure of Emrg. Steering Press. Sensor
— [DHUDKB] Emrg. Steering Press. S. Short Circuit
— [DJF1KA] Disconnection of Fuel Level Sensor
— [DK55KA] Failure of FNR Lever Potentio
— [DK55KY] Hot Short of FNR Lever Potentio Circuit
— [DK55L5] Failure of FNR Lever Potentio
— [DK59KA] Failure of Boom Lever Potentio (Main)
— [DK59KY] Hot Short of Boom Lever Potentio (Main)
— [DK59L8] Boom Lever Potentio (Main & Sub) Disagree
— [DK5AKA] Failure of Boom Lever Potentio (Sub)
— [DK5AKY] Hot Short of Boom Lever Potentio (Sub)
— [DK5BKA] Failure of Bucket Lever Potentio (Main)
— [DK5BKY] Hot Short of Bucket Lever Potentio (Main)
— [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree
— [DK5CKA] Failure of Bucket Lever Potentio (Sub)
— [DK5CKY] Hot Short of Bucket Lever Potentio (Sub)
— [DK5DKA] Failure of 3rd Lever Potentio (Main)
— [DK5DKY] Hot Short of 3rd Lever Potentio (Main)
— [DK5DL8] 3rd Lever Potentio (Main&Sub) Disagree
— [DK5EKA] Failure of 3rd Lever Potentio (Sub)
— [DK5EKY] Hot Short of 3rd Lever Potentio (Sub)
— [DK5KKA] Failure of 4th Lever Potentio (Main)
— [DK5KKY] Hot Short of 4th Lever Potentio (Main)
— [DK5KL8] 4th Lever Potentio (Main&Sub) Disagree
— [DK5LKA] Failure of 4th Lever Potentio (Sub)
— [DK5LKY] Hot Short of 4th Lever Potentio (Sub)
— [DKA0KA] Failure of Boom Angle Sensor
— [DKA0KY] Hot Short of Boom Angle Sensor Circuit
— [DKA0L0] Boom Angle Sensor Dislocation
— [DKA1KA] Failure of Bucket Angle Sensor
— [DKA1KY] Hot Short of Bucket Angle Sensor Circuit
— [DLF1KA] Disconnection of T/M Input Speed Sensor
— [DLF1LC] Failure of T/M Input Speed Sensor
— [DLM3KA] Disconnection of Radiator Fan Speed Sensor
— [DLM3LC] Failure of Radiator Fan Speed Sensor
— [DLT3KA] Disconnection of Output Speed Sens. (Main)
— [DLT3LC] Failure of Output Speed Sensor (Main)
— [DPQ1KR] LIN Discon (Switch Panel)
— [DPQ2KR] LIN Discon (LED Unit)
— [DPQ3KR] LIN DIscon (Rear View Monitor)
— [DJS0KR] CAN2 Discon (Meter Unit)
— [DT20KB] Ground Fault of T/M Cut Off Indicator
— [DT22KB] Ground Fault of Work Equip. Lock Indic.
— [DV00KB] Ground Fault of Buzzer Output
— [DW4PKA] Disconnection of Boom EPC Solenoid (Raise)
— [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise)
— [DW4PKY] Hot Short of Boom EPC Solenoid (Raise)
— [DW4QKA] Disconnection of Boom EPC Solenoid (Lower)
— [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower)
— [DW4QKY] Hot Short of Boom EPC Solenoid (Lower)
— [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt)
— [DW4RKB] Ground Fault of Bucket EPC Sol. (Tilt)
— [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt)
— [DW4SKA] Disconnection of Bucket EPC. Sol (Dump)
— [DW4SKB] Ground Fault of Bucket EPC Sol. (Dump)
— [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump)
— [DW7BKA] Disconnection of Fan Reverse Solenoid
— [DW7BKB] Ground Fault of Radiator Fan Reverse Solenoid
— [DW7BKY] Hot Short of Radiator Fan Rev. Sol.
— [DWM1KA] Disconnection of Neutral Lock Solenoid
— [DWM1KB] Ground Fault of Neutral Lock Solenoid
— [DWM1KY] Hot Short of Neutral Lock Solenoid
— [DWN6KA] Disconnection of Detent Solenoid (Boom)
— [DWN6KB] Ground Fault of Detent Solenoid (Boom)
— [DWN6KY] Hot Short of Detent Solenoid (Boom)
— [DWN8KA] Disconnection of Detent Solenoid (Bucket)
— [DWN8KB] Ground Fault of Detent Solenoid (Bucket)
— [DWN8KY] Hot Short of Detent Solenoid (Bucket)
— [DX16KA] Disconnection of Radiator Fan Pump EPC Solenoid
— [DX16KB] Ground Fault of Radiator Fan Pump EPC Solenoid
— [DX16KY] Hot Short of Radiator Fan Pump EPC Solenoid
— [DXA1KA] Disconnection of Loader Pump EPC Solenoid
— [DXA1KB] Ground Fault of Loader Pump EPC Solenoid
— [DXA1KY] Hot Short of Loader Pump EPC Solenoid
— [DXANKA] Disconnection of Steering Pump EPC Solenoid
— [DXANKB] Ground Fault of Steering Pump EPC Solenoid
— [DXANKY] Hot Short of Steering Pump EPC Solenoid
— [DXH1KA] Disconnection of ECMV Solenoid (Lockup)
— [DXH1KB] Ground Fault of ECMV Solenoid (Lockup)
— [DXH1KY] Hot Short of ECMV Solenoid (Lockup)
— [DXH4KA] Disconnection of ECMV Solenoid (1st)
— [DXH4KB] Ground Fault of ECMV Solenoid (1st)
— [DXH4KY] Hot Short of ECMV Solenoid (1st)
— [DXH5KA] Disconnection of ECMV Solenoid (2nd)
— [DXH5KB] Ground Fault of ECMV Solenoid (2nd)
— [DXH5KY] Hot Short of ECMV Solenoid (2nd)
— [DXH6KA] Disconnection of ECMV Solenoid (3rd)
— [DXH6KB] Ground Fault of ECMV Solenoid (3rd)
— [DXH6KY] Hot Short of ECMV Solenoid (3rd)
— [DXH7KA] Disconnection of ECMV Solenoid (Reverse)
— [DXH7KB] Ground Fault of ECMV Solenoid (Reverse)
— [DXH7KY] Hot Short of ECMV Solenoid (Reverse)
— [DXH8KA] Disconnection of ECMV Solenoid (Forward)
— [DXH8KB] Ground Fault of ECMV Solenoid (Forward)
— [DXH8KY] Hot Short of ECMV Solenoid (Forward)
— [DXHHKA] Disconnection of ECMV Solenoid (4th)
— [DXHHKB] Ground Fault of ECMV Solenoid (4th)
— [DXHHKY] Hot Short of ECMV Solenoid (4th)
— [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT)
— [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)
— [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT)
— [DXHKKA] Disconnection of 3rd EPC Solenoid (RET)
— [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET)
— [DXHKKY] Hot Short of 3rd EPC Solenoid (RET)
— [DXJEKA] Disconnection of 4th EPC Solenoid (EXT)
— [DXJEKB] Ground Fault of 4th EPC Solenoid (EXT)
— [DXJEKY] Hot Short of 4th EPC Solenoid (EXT)
— [DXJFKA] Disconnection of 4th EPC Solenoid (RET)
— [DXJFKB] Ground Fault of 4th EPC Solenoid (RET)
— [DXJFKY] Hot Short of 4th EPC Solenoid (RET)
— [DY30MA] Malfunction 1 of Emerg. Steering Motor
— [DY30MC] Malfunction 2 of Emerg. Steering Motor
— [DY30ME] Emergency Steering Long-Time Activated
— [H2K0KA] Failure of Quick Coupler Lock Signal
— [H2K0KY] Hot Short of Quick Coupler Lock Signal
— [LA00L3] Failure of Fan Reverse
— TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
— E-1 Engine Does Not Start
— E-2 Manual Preheating System Does Not Work
— E-3 Automatic Preheating System Does Not Work
— E-4 While Preheating is Working, Preheating Monitor Does Not Light Up
— E-5 All of LCD Unit, LED Unit, and Meter Unit on Machine Monitor Display Nothing
— E-6 LCD Unit on Machine Monitor Displays Nothing
— E-7 Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Out or Flickers)
— E-8 LCD on Machine Monitor Does Not Display Properly
— E-9 Meter Unit Display on Machine Monitor is Abnormal
— E-10 Night Lighting Lamp of Meter Unit on Machine Monitor is Abnormal
— E-11 Caution LED on Machine Monitor is Abnormal
— E-12 LED of Switch Panel on Machine Monitor is Abnormal or Switches Does Not Operate Properly
— E-13 Two Switches Operation of Switch Panel on Machine Monitor Does Not Function
— E-14 Switch Panel Buzzer of Machine Monitor is Abnormal
— E-15 Rear View Monitor Does Not Light Up or Backlight Flickers
— E-16 Rear View Monitor Images are not Displayed Clearly
— E-17 Rear View Monitor Brightness cannot be Adjusted
— E-18 Night Lighting Lamp of Rear View Monitor is Abnormal
— E-19 Some Items of Gauges and Caution Lamps on Machine Monitor are not Displayed Properly
— E-20 Parking Brake Indicator Lamp does not Light When the Parking Brake is Set to ON (Parking) Position
— E-21 When Brake Accumulator Oil Pressure Drops, the Brake Oil Pressure Caution Lamp does not Light
—- Front Brake
—- Rear Brake
— E-22 Air Cleaner Clogging Indicator Lamp does not Light
— E-23 Radiator Coolant Level Caution Lamp does not Light
— E-24 Indication of Hydraulic Oil Temperature Gauge does not Increase, or Hydraulic Oil Temperature Caution Lamp does not Light
— E-25 Indication of Torque Converter Oil Temperature Gauge does not Increase, or Torque Converter Oil Temperature Caution Lamp does not Light
— E-26 Fuel Level Gauge does not Indicate Correct Level
— E-27 Seat Belt Caution Lamp Indication is Abnormal
— E-28 Horn does not Sound
— E-29 Horn does not Stop Sounding
— E-30 Alarm Buzzer does not Sound
— E-31 When Starting Switch is in ON Position, Alarm Buzzer does not Stop Sounding
— E-32 Kick-Down does not Work when kick-Down Switch is Turned ON
— E-33 The Hold Switch does not Work When it is Pressed
— E-34 Parking Brake does not Work Even if it is Applied, or the Brake Drags When Parking Brake is Released and FR Drive is Operated
— E-35 Transmission Cut-Off Mode is not Selected or not Released
— E-36 Transmission Cut-Off Setting cannot be Released
— E-37 Directional Selector (FNR) Switch Mode is not Selected or not Released
— E-38 When Operating Engine Power Selection Switch, Engine Power Selection Function does not Operate Properly
— E-39 Flow of Loader Pump does not Increase from the Minimum Rate
— E-40 ECSS Function cannot be Selected or cannot be Released
— E-41 None of Headlamp, Clearance Lamp, and Tail Lamp Light
— E-42 Clearance Lamp and Tail Lamp do not Light Up or go Out
— E-43 Both “High and Low Beams” of Headlamp do not Light Up or Go Out
— E-44 The Headlamp “Low Beam” does not Light Up or Go Out
— E-45 The Headlamp “High Beam” does not Light Up or Go Out
— E-46 Front Working Lamp does not Light Up or Go Out
— E-47 Rear Working Lamp does not Light Up or Go Out
— E-48 All of Turn Signal Lamps and Hazard Lamps do not Light Up or Go Out
— E-49 Turn Signal Lamps do not Light Up or Go Out
— E-50 Hazard Lamp does not Light Up or Go Out
— E-51 Brake Lamp does not Light Up or Stays Lighted
— E-52 Back-Up Lamp does not Light or Continues To Light
— E-53 Back-Up Buzzer does not Sound or Continues to Sound
— E-54 Front Wiper does not Operate
— E-55 Rear Wiper does not Operate
— E-56 Window Washer does not Operate
— E-57 KOMTRAX System does not Operate Properly
— TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
— Information Mentioned in Troubleshooting Table (H-mode)
— System Chart of Hydraulic and Mechanical Systems
— Failure Mode and Cause Table
— H-1 Machine Does Not Start
— H-2 Torque Converter Lockup is Not Disengaged (Engine Stalls)
— H-3 Torque Converter Lockup Clutch is Not Engaged
— H-4 Travel Speed is Slow, Bucket Thrusting Force is Weak, Gradability is Low, or Gear Speed Does Not Shift
— H-5 Large Shock is Made When Machine Starts or Gear is Shifted
— H-6 Machine Starts or Gear Speed Shifts with Long Time Lag
— H-7 Torque Converter Oil Temperature is High
— H-8 Machine Does Not Turn
— H-9 Turning Response is Poor
— H-10 Steering Wheel is Heavy to Turn
— H-11 Machine Sways or Large Shocks Are Made While Machine Turns
— H-12 Turning Radius Differs Between Right and Left Turns
— H-13 Wheel Brakes Do Not Work or Are Weak
— H-14 Wheel Brakes Are Not Released or Drag
— H-15 Parking Brake Does Not Work or It is Weak
— H-16 Parking Brake is Not Released or It Drags (Including Emergency Release System)
— H-17 Boom Does Not Rise
— H-18 Boom Moves Slow or Boom Lacks Lifting Force
— H-19 Rising Boom Slows Down at Certain Height
— H-20 Boom Cylinders Do Not Serve to Hold Bucket on Ground
— H-21 Hydraulic Drift of Boom is Large
— H-22 Boom Moves Up and Down During Operation
— H-23 Bucket Does Not Tilt Back
— H-24 Bucket Moves Slow or Bucket Lacks Tilt-Back Force
— H-25 Bucket Decelerates During Tilt-Back Operation
— H-26 Bucket Cylinder Does Not Hold Bucket on Ground
— H-27 Hydraulic Drift of Bucket is Large
— H-28 Bucket Tilts Back and Forth During Carrying Load (Work Equipment Valve in “Hold”)
— H-29 Boom and Bucket Control Levers Do Not Move Smoothly and Heavy to Move
— H-30 Operating Work Equipment Causes Engine Speed to Lower Significantly or Engine to Stall
— H-31 Large Shocks Are Made When Work Equipment Starts to Move and Stops
— H-32 When Certain Work Equipment Stalls Hydraulically, Other Work Equipment Moves
— H-33 E.C.S.S. (Travel Damper) Does Not Work and Machine Pitches and Bounces
— H-34 Air Conditioner Does Not Work While Cooling Fan Rotates in Reverse Mode
— H-35 Fan Speed is Abnormal (Too High or Low, or Fan Does Not Rotate)
— H-36 Unusual Noise is Heard from Around Fan
— TROUBLESHOOTING OF ENGINE (S-MODE)
— Information Mentioned in Troubleshooting Table (S-Mode)
— S-1 When Starting Switch is Turned to START Position, Engine Does Not Crank
— S-2 When Engine Cranks, but No Exhaust Smoke Comes Out
— S-3 Fuel is Being Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)
— S-4 Engine Startability is Poor
— S-5 Engine Does Not Pick Up Smoothly
— S-6 Engine Stops During Operation
— S-7 Engine Runs Rough or is Unstable
— S-8 Engine Lacks Power
— S-9 Exhaust Smoke is Black (KDPF Clogs Up Early)
— S-10 Engine Oil Consumption is Excessive
— S-11 Oil Becomes Contaminated Quickly
— S-12 Fuel Consumption is Excessive
— S-13 Oil is in Coolant (or Coolant Spurts or Coolant Level Goes Down)
— S-14 Engine Oil Pressure Drops
— S-15 Fuel Mixes in Engine Oil
— S-16 Water mixes into Engine Oil (Milky)
— S-17 Coolant Temperature Rises Too High (Overheating)
— S-18 Unusual Noise is Heard
— S-19 Vibration is Excessive
— S-20 Air Cannot Be Bled From Circuit
— S-21 Active Regeneration is Executed Frequently
— S-22 Active Regeneration Takes Time
— S-23 White Smoke is Exhausted During Active Regeneration
– 50 DISASSEMBLY AND ASSEMBLY
— HOW TO READ THIS SECTION
— Removal and Installation of Assemblies
—- Special Tools
—- Removal
—- Installation
— Disassembly and Assembly of Assemblies
—- Special Tools
—- Disassembly
—- Assembly
— COATING MATERIALS LIST
— SPECIAL TOOLS LIST
— SKETCHES OF SPECIAL TOOLS
— CONNECTOR REPAIR PROCEDURES
— Stripping Insulation
— Wire Inspection
— Contact Terminal Removal (HD30 Type)
— Crimping Contact Terminal (HD30 Type)
— Insertion Of Contact Terminal (HD30 Type)
— Contact Terminal Removal (DT Type)
— Crimping Contact Terminal (DT Type)
— Insertion Of Contact Terminal (DT Type)
— ENGINE AND COOLING SYSTEM
— Supply Pump Assembly
—- Removal
—- Installation
— Injector Assembly
— Special Tools
—- Removal
—- Installation
— Cylinder Head Assembly
—- Removal
—- Installation
— Engine Hood
—- Removal
—- Installation
— Grille Assembly
—- Removal
—- Installation
— Cooling System Assembly
—- Removal
—- Installation
— Radiator Core Assembly
—- Removal
—- Installation
— After Cooler
—- Removal
—- Installation
— Hydraulic Oil Cooler
—- Removal
—- Installation
— Fuel Cooler Assembly
—- Removal
—- Installation
— Engine, Torque Converter and Transmission Assemblies
—- Removal
—- Installation
— Disconnect and Connection of Engine, Torque Converter and Transmission Assembly
—- Disconnection
—- Connection
— Engine Front Oil Seal
—- Removal
—- Installation
— Engine Rear Oil Seal
—- Removal
—- Installation
— Cooling Fan and Fan Motor Assembly
—- Removal
—- Installation
— KDPF Assembly
—- Removal
—- Installation
— Disassembly and Assembly of KDPF Assembly
—- Disassembly
—- Assembly
— KCCV Assembly
—- Removal
—- Installation
— Air Cleaner Assembly
—- Removal
—- Installation
— Fuel Tank
—- Removal
—- Installation
— POWER TRAIN
— Disassembly and Assembly of Torque Converter Assembly
—- Disassembly
—- Assembly
— Transmission
—- Disassembly
—- Assembly
— Transmission Clutch Pack Assembly
—- Disassembly
—- Assembly
— Differential Assembly
—- Disassembly
—- Assembly
— Parking Brake
—- Disassembly
—- Assembly
— Front Axle
—- Removal
—- Installation
— Rear Axle
—- Removal
—- Installation
— Axle Housing
—- Disassembly
—- Assembly
— STEERING SYSTEM
— Steering Valve Assembly
—- Removal
—- Installation
— BRAKE SYSTEM
— Parking Brake Discs and Plates
—- Removal
—- Drain the oil from the transmission case.
—- Installation
— UNDERCARRAGE AND FRAME
— Center Hinge Pin
—- Installation
— Counterweight
—- Removal
—- Installation
— Full-Length Fender Assembly
—- Removal
—- Installation
— HYDRAULIC SYSTEM
— Hydraulic Tank Assembly
—- Removal
—- Installation
— Work Equipment Control Valve
—- Removal
—- Installation
— Power Train Pump and Work Equipment Pump Assembly
—- Removal
—- Installation
— Steering Pump And Cooling Fan Pump Assembly
—- Installation
— Hydraulic Cylinder
—- Disassembly
—- Assembly
— WORK EQUIPMENT
— Work Equipment Assembly
—- Removal
—- Installation
— CAB AND ATTACHMENTS
— Cab and Floor Frame
—- Removal
—- Installation
— Cab Glass (Stuck Window Glass)
—- Removal
—- Installation
— Operator Seat Assembly
—- Removal
—- Installation
— Seat Belt
—- Removal
—- Installation
— ELECTRICAL SYSTEM
— Machine Monitor Assembly
—- Removal
—- Installation
— Engine Controller Assembly
—- Removal
—- Installation
— Work Equipment Controller Assembly
—- Removal
—- Installation
— Transmission Controller Assembly
—- Removal
—- Installation
— Monitor Controller Assembly
—- Removal
—- Installation
— Mass Air Flow and Temperature Sensor
—- Removal
—- Installation
— KOMTRAX Terminal Assembly
—- Removal
—- Installation
– 60 MAINTENANCE STANDARD
— ENGINE AND COOLING SYSTEM
— Engine Related Parts
— Cooling Fan Clamp
— Servo Valve
— Cooling Fan Motor
— POWER TRAIN
— Drive Shaft
— Torque Converter
— Transmission
— Forward and Reverse Clutches
— 1st and 4th Clutches
— 2nd and 3rd Clutches
— Transmission Control Valve
— Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV
— Lockup Clutch ECMV
— Main Relief and Torque Converter Relief Valve
— Differential
—- Front Differential (Standard: Conventional Differential)
—- Rear differential (Standard: Conventional Differential)
— Limited Slip Differential
—- Front Axle
—- Rear Axle
— Final Drive
— STEERING SYSTEM
— Steering Column
— Steering Pump
— Pump Body
— Servo Valve
— Steering Valve
— Steering Cylinder
— Emergency Steering Pump (if equipped)
— Brake System
—- Charge Valve
— Brakes
—- Front Brake
—- Rear Brake
—- Parking Brake
—- Parking Brake Solenoid Valve
— UNDERCARRIAGE AND FRAME
— Axle Mount and Center Hinge Pin
— HYDRAULIC SYSTEM
— Hydraulic Tank
— Double Type Gear Pump
—- Power Train Charge Pump and Power Train Lubrication Pump
— WORK EQUIPMENT PUMP
— Pump Body
— Servo Valve
— CONTROL VALVE
— STABILIZER VALVE
— WORK EQUIPMENT
— Work Equipment Linkage
— BUCKET
— WORK EQUIPMENT CYLINDER
— Boom Cylinder
— Bucket Cylinder
– 80 AIR CONDITIONING
— AIR CONDITIONER
— Precautions for Refrigerant
— Air Conditioner Component
— Structure and Function of Refrigeration System
— Overview of Refrigeration System
— Air Conditioner Unit
—- Function
— Functions of Major Components
—- Evaporator
—- Heater Core
—- Evaporator Temperature Sensor
—- Inner Sensor
—- Blower Amplifier
—- Blower Off Relay
—- Compressor Clutch Relay
—- Servomotor
—- Expansion Valve
—- Dual Pressure Switch
—- Air Conditioner Controller
—- Compressor
—- Condenser
—- Receiver
—- Sunlight Sensor
— Outside Air Temperature Sensor
— Inspection and Troubleshooting Procedure of Air Conditioner
—- Basic Inspection and Troubleshooting Sequence
— Air Conditioner Circuit Diagram and Arrangement of Connector Pins
— System Diagram
— Parts and Connectors Layout
— Testing with Self-Diagnosis Function
— How to Enter Air Conditioner “Electrical Systems” Screen in Service Mode of the Machine Monitor
— Testing Temperature Control System
—- Testing
— Testing Vent (Mode) Changeover
—- Testing
— Testing FRESH/RECIRC Air Changeover
— Testing Relay
— Troubleshooting Chart 1
— Troubleshooting Chart 2
— Information Mentioned in Troubleshooting Table
—- Information in Troubleshooting Table
— Troubleshooting with Gauge Pressure
— Testing Refrigerant Pressure
— Precautions for Disconnecting and Connecting Refrigerant Piping
—- Disconnection
—- Connection
— Filling Compressor Oil
– 90 DIAGRAMS AND SCHEMATICS
— HYDRAULIC SYSTEM
— Hydraulic Circuit Diagram
— Power Train Hydraulic Circuit Diagram
— ELECTRICAL SYSTEM
— Symbols in Electrical Circuit Diagram
— Electrical Circuit Diagram (1/5)
— Electrical Circuit Diagram (2/5)
— Electrical Circuit Diagram (3/5)
— Electrical Circuit Diagram (4/5)
— Electrical Circuit Diagram (5/5)
— Electrical Circuit Floor Diagram (1/8)
— Electrical Circuit Floor Diagram (2/8)
— Electrical Circuit Floor Diagram (3/8)
— Electrical Circuit Floor Diagram (4/8)
— Electrical Circuit Floor Diagram (5/8)
— Electrical Circuit Floor Diagram (6/8)
— Electrical Circuit Floor Diagram (7/8)
— Electrical Circuit Floor Diagram (8/8)
— Electrical Circuit Air Conditioner Diagram