Komatsu Wheel Loader WA475-11 WA475-11E0 WA485-11 WA485-11E0 Shop Manual SEN06986-06

Description

Contents:
00 Index and Foreword
Index
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions for Disposing of Waste Materials
Engine Technology to Conform Exhaust Gas Emission
Precautions for DEF
Store DEF
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect Push-Pull Type Coupler
Precautions for Disconnection and Connection of Connectors
How to Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect and Connect Connector with Lock to Push
How to Disconnect and Connect Connector with Housing to Rotate
How to Read the Codes for Electric Cable
Explanation of Terms for Maintenance Standard
Standard Tightening Torque Table
Conversion Table
Abbreviation List
01 Specifications
Table of Contents
Specifications
Specification Drawing
Specifications
Weight Table
Fuel, Coolant, Lubricants (WA475-11, WA485-11)
Fuel, Coolant, Lubricants (WA475-11E0)
Fuel, Coolant, Lubricants (WA485-11E0)
10 Structure and Function
Table of Contents
Urea SCR System
Layout Drawing of Urea SCR System
Urea SCR System Diagram
Function of Urea SCR System
Component Parts of Urea SCR System
Boot-up System
Layout Drawing of Boot-up System
System Operating Lamp System
Battery Disconnect Switch
Preheating System
Starter Signal Unit System
Remote Courtesy Lights System
Remote Open Door System
Engine System
Layout Drawing of Engine System
Engine Control System
Component Parts of Engine System
Cooling System
Layout Drawing of Cooling System
Cooling Fan Control System
Component Parts of Cooling System
Control System
Layout Drawing of Control System
Machine Monitor System
Rearview Monitor System
KOMTRAX System
Seat Belt Reminder System
Load Meter System
Rear Object Detection System
Component Parts of Control System
Hydraulic System
Layout Drawing of Hydraulic System
CLSS
Work Equipment Pump and Steering Pump Control System
Component Parts of Hydraulic System
Total Control System
System Diagram of Total Control System
Independent Work Equipment Control Function
Power Mode Selector Function
Overheat Prevention Function
Output Limitation Function for Low Temperature
Work Equipment Speed Level
Power Train System
Layout Drawing of Power Train System
Operation of Power Train System
HST Charge System
Pump Motor Control System
Transmission Gear Shift Control System
Transmission Protection Function
Directional Selector Switch Control Function
Traction Control System
KHMT System
Component Parts of Power Train System
Work Equipment System
Layout Drawing of Work Equipment System
Work Equipment Control System
Work Equipment Neutral Lock System
Remote Positioner System
Automatic Bucket Shake System
Bucket Positioner and Boom Positioner
Auto-Digging System
ECSS
Quick Coupler System
Component Parts of Work Equipment System
Steering System
Layout Drawing of Steering System (Steering Wheel Specification)
Layout Drawing of Steering System (AFJS Specification)
Secondary Steering System
AFJS
AFJS System
Steering Column
Component Parts of Steering System
Brake System
Layout Drawing of Brake System
Parking Brake Control System
Component Parts of Brake System
Auto-Greasing System
Layout Drawing of Auto-Greasing System
Specifications of Auto-Greasing System
Function of Auto-Greasing System
Auto-Greasing System
Undercarriage and Frame
Frame, Axle Mount and Center Hinge Pin
Tires
Work Equipment
Structure of Work Equipment
Structure of Bucket
CAB Related Parts
ROPS CAB
20 Standard Value Table
Table of Contents
Standard Value Table for Engine
Standard Value Table for Engine: WA475-11
Standard Value Table for Engine: WA475-11E0
Standard Value Table for Engine: WA485-11
Standard Value Table for Engine: WA485-11E0
Standard Value Table for Machine
Standard Value Table for Machine: WA475-11
Standard Value Table for Machine: WA475-11E0
Standard Value Table for Machine: WA485-11
Standard Value Table for Machine: WA485-11E0
Machine Posture and Procedures to Measure Performance
30 Testing and Adjusting
Table of Contents
Precautions Before Work
Related Information on Testing and Adjusting
Differences In Machine Monitor Symbols
Tools for Testing and Adjusting
Sketch of Tools for Testing and Adjusting
Engine and Cooling System
Examine Engine Speed
Examine Boost Pressure
Examine Exhaust Gas Temperature
Examine Exhaust Gas Color
Examine and Adjust Valve Clearance
Examine Compression Pressure
Examine Blowby Pressure
Examine Engine Oil Pressure
Examine Fuel Pressure
Examine Fuel Return Rate and Leakage
Bleed Air from Fuel System
Examine Fuel Circuit for Leakage
Handle Cylinder Cut-out Mode Operation
Handle No-Injection Cranking Operation
Examine KDPF, SCR and Muffler Stack for Looseness and Damage
Examine Installed Condition of Cylinder Heads and Manifolds
Examine Engine Piping for Damage and Looseness
Examine Alternator Belt
Examine Automatic Tensioner
Clean Fuel Doser
Write Injector Compensation Value to Engine Controller
Examine SCR Related Function
Clean DEF Tank
Clean DEF Pump
Power Train
Examine Power Train Oil Pressure
Examine Nitrogen Gas Pressure in Transmission Accumulator (Made by HYDAC) and Charge Nitrogen Gas
Examine and Adjust HST Oil Pressure
Adjust Transmission Input Shaft Speed Sensor
Adjust Transmission M2 Speed Sensor
Flush Transmission Hydraulic Circuit
Examine Oil Sump in Flywheel Housing
Examine Drive Shaft for Looseness, Backlash, and Damage
How to Move When Electric System Failure Occurs
Steering System
Examine Steering Wheel
Examine and Adjust Steering Circuit Oil Pressure
Bleed Air from Steering Cylinder Circuit
Examine and Adjust Steering Stop Valve
Examine and Adjust Articulate Angle Sensor and AFJS Link Angle Sensor
Examine and Adjust Steering Circuit Oil Pressure (AFJS Specification)
Bleed Air from Steering Valve (AFJS Specification)
Examine and Adjust Length of AFJS Link Rod (AFJS Specification)
Examine and Adjust AFJS Frame End Angle (AFJS Specification)
Examine and Adjust Steering Speed (AFJS Specification)
Brake System
Release Remained Pressure in Brake Accumulator Circuit
Examine Wheel Brake Oil Pressure
Examine and Adjust Accumulator Charge Pressure
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas
Bleed Air from Brake Circuit
Examine Brake Performance
Examine Brake Pedal
Examine Pressure Decrease of Wheel Brake
Examine Wear of Wheel Brake Disc
Examine Parking Brake Oil Pressure
Examine Parking Brake Performance
Release Parking Brake Manually
Examine Wear Volume of Parking Brake Disc
Hydraulic System
Release Remained Pressure from Work Equipment Circuit
Examine and Adjust Work Equipment Oil Pressure
Examine Work Equipment EPC Oil Pressure
Bleed Air from Work Equipment Circuit
Examine Cooling Fan Speed
Examine Cooling Fan Circuit Oil Pressure
Bleed Air from Cooling Fan Circuit
Examine ECSS Accumulator Nitrogen Gas Pressure and Charge Accumulator with Nitrogen Gas
Work Equipment
Examine and Adjust Bucket Potentiometer Lever
Examine and Adjust Boom Potentiometer Lever
CAB Related Parts
Examine Directional Lever
Examine Work Equipment Control Lever
Examine AFJS Lever (AFJS Specification)
Examine Flip-up Lever (AFJS Specification)
Examine AFJS Lever Stand (AFJS Specification)
Adjust Rubber Stopper of AFJS Lever Stand Lock
Eliminate Noise When AFJS Lever Stand Rolls
Examine and Adjust AFJS Lever Angle Sensor (AFJS Specification)
Adjust Play of Operator Seat
Adjust Adjustment Noise of Operator Seat
Adjust Mirrors
Adjust Operator Cab Door
Electrical System
Set and Adjust Each Equipment
Replace Steering Related Device, and Examination and Adjustment Items During Disassembly and Assembly (AFJS Specification)
Adjustment by S-PRIT
Set and Operate Machine Monitor
Set and Operate by SDT
How to Start Up KOMTRAX System
How to Stop Use of KOMTRAX System
Set Region of Bluetooth(R) Compatible Radio
Handle Voltage Circuit of Engine Controller
Handle Battery Disconnect Switch
Examine Diodes
Auto-Greasing System
Bleed the Air in Auto-Greasing System
Correspondence in Case of Grease Leakage from over Pressure Protection Valve
Change Lubrication Time and Lubrication Interval
Examine and Fill Auto-Greasing
Pm Clinic
Pm Clinic Service
40 Troubleshooting
Table of Contents
Precautions Before Work
Related Information for Troubleshooting
Precautions for Troubleshooting
Sequence of Events in Troubleshooting
General Troubleshooting Points
Troubleshooting Points for Urea SCR System
Inspection Before Troubleshooting
Inspection Procedure Before Troubleshooting
Test in Accordance with Testing Procedure
Preparation for Troubleshooting of Electrical System
Inspection Procedure of Electrical System
Procedure for Troubleshooting
Adjustment After Troubleshooting
Symptom and Troubleshooting Numbers
Information Shown in Troubleshooting Table
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness
Connector List and Layout
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location Table
Precautions When You Clean and Replace KDPF (SF and KDOC)
Prepare Troubleshoot Machine Monitor
Procedure to Make Harness Checker on Machine Monitor LCD Unit
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883], [CA3135], and [CA5715])
Failure Code Table
Troubleshooting by Failure Code (Display of Code)
Failure Code [1500L0]
Failure Code [1500MA]
Failure Code [1500MC]
Failure Code [159ZMB]
Failure Code [15F0MC]
Failure Code [1AR0MA]
Failure Code [1AR0MB]
Failure Code [2F00MB]
Failure Code [2G42ZG]
Failure Code [2G43ZG]
Failure Code [6071NX]
Failure Code [879AKA]
Failure Code [879AKB]
Failure Code [879BKA]
Failure Code [879BKB]
Failure Code [879CKA]
Failure Code [879CKB]
Failure Code [879DKZ]
Failure Code [879EMC]
Failure Code [879FMC]
Failure Code [989800]
Failure Code [989A00]
Failure Code [989L00]
Failure Code [989M00]
Failure Code [989N00]
Failure Code [A1U0N3]
Failure Code [A1U0N4]
Failure Code [AA10NX]
Failure Code [AB00KE]
Failure Code [AB00KY]
Failure Code [AQ10MB]
Failure Code [AQ10N3]
Failure Code [AS00R2]
Failure Code [AS00R3]
Failure Code [AS00R4]
Failure Code [AS00R5]
Failure Code [AS00R6]
Failure Code [AS00ZK]
Failure Code [AS10KM]
Failure Code [AS10NR]
Failure Code [AS10NT]
Failure Code [B@BAZG]
Failure Code [B@BAZK]
Failure Code [B@BCNS]
Failure Code [B@BCQA]
Failure Code [B@BCZK]
Failure Code [B@C6NS]
Failure Code [B@C7NS]
Failure Code [B@CFNS]
Failure Code [B@HANS]
Failure Code [C12643]
Failure Code [C12644]
Failure Code [C14254]
Failure Code [C14481]
Failure Code [CA122]
Failure Code [CA123]
Failure Code [CA135]
Failure Code [CA141]
Failure Code [CA144]
Failure Code [CA145]
Failure Code [CA153]
Failure Code [CA154]
Failure Code [CA187]
Failure Code [CA221]
Failure Code [CA222]
Failure Code [CA227]
Failure Code [CA234]
Failure Code [CA238]
Failure Code [CA239]
Failure Code [CA249]
Failure Code [CA256]
Failure Code [CA295]
Failure Code [CA322]
Failure Code [CA323]
Failure Code [CA324]
Failure Code [CA325]
Failure Code [CA331]
Failure Code [CA332]
Failure Code [CA343]
Failure Code [CA351]
Failure Code [CA352]
Failure Code [CA386]
Failure Code [CA431]
Failure Code [CA432]
Failure Code [CA449]
Failure Code [CA451]
Failure Code [CA452]
Failure Code [CA515]
Failure Code [CA516]
Failure Code [CA553]
Failure Code [CA555]
Failure Code [CA556]
Failure Code [CA559]
Failure Code [CA584]
Failure Code [CA585]
Failure Code [CA595]
Failure Code [CA687]
Failure Code [CA689]
Failure Code [CA691]
Failure Code [CA692]
Failure Code [CA697]
Failure Code [CA698]
Failure Code [CA731]
Failure Code [CA741]
Failure Code [CA742]
Failure Code [CA743]
Failure Code [CA778]
Failure Code [CA1117]
Failure Code [CA1358]
Failure Code [CA1359]
Failure Code [CA1669]
Failure Code [CA1673]
Failure Code [CA1677]
Failure Code [CA1678]
Failure Code [CA1682]
Failure Code [CA1686]
Failure Code [CA1695]
Failure Code [CA1696]
Failure Code [CA1713]
Failure Code [CA1714]
Failure Code [CA1715]
Failure Code [CA1776]
Failure Code [CA1777]
Failure Code [CA1843]
Failure Code [CA1844]
Failure Code [CA1879]
Failure Code [CA1881]
Failure Code [CA1883]
Failure Code [CA1885]
Failure Code [CA1887]
Failure Code [CA1921]
Failure Code [CA1922]
Failure Code [CA1923]
Failure Code [CA1924]
Failure Code [CA1925]
Failure Code [CA1927]
Failure Code [CA1928]
Failure Code [CA1942]
Failure Code [CA1963]
Failure Code [CA1977]
Failure Code [CA2185]
Failure Code [CA2186]
Failure Code [CA2249]
Failure Code [CA2265]
Failure Code [CA2266]
Failure Code [CA2638]
Failure Code [CA2639]
Failure Code [CA2732]
Failure Code [CA2733]
Failure Code [CA2741]
Failure Code [CA2765]
Failure Code [CA2771]
Failure Code [CA2878]
Failure Code [CA2881]
Failure Code [CA2973]
Failure Code [CA2976]
Failure Code [CA3133]
Failure Code [CA3134]
Failure Code [CA3135]
Failure Code [CA3146]
Failure Code [CA3147]
Failure Code [CA3148]
Failure Code [CA3151]
Failure Code [CA3165]
Failure Code [CA3167]
Failure Code [CA3232]
Failure Code [CA3235]
Failure Code [CA3239]
Failure Code [CA3241]
Failure Code [CA3251]
Failure Code [CA3253]
Failure Code [CA3255]
Failure Code [CA3311]
Failure Code [CA3312]
Failure Code [CA3313]
Failure Code [CA3314]
Failure Code [CA3315]
Failure Code [CA3316]
Failure Code [CA3317]
Failure Code [CA3318]
Failure Code [CA3319]
Failure Code [CA3321]
Failure Code [CA3322]
Failure Code [CA3375]
Failure Code [CA3376]
Failure Code [CA3419]
Failure Code [CA3421]
Failure Code [CA3497]
Failure Code [CA3498]
Failure Code [CA3545]
Failure Code [CA3547]
Failure Code [CA3558]
Failure Code [CA3559]
Failure Code [CA3567]
Failure Code [CA3568]
Failure Code [CA3571]
Failure Code [CA3572]
Failure Code [CA3574]
Failure Code [CA3575]
Failure Code [CA3577]
Failure Code [CA3578]
Failure Code [CA3583]
Failure Code [CA3596]
Failure Code [CA3649]
Failure Code [CA3681]
Failure Code [CA3682]
Failure Code [CA3725]
Failure Code [CA3748]
Failure Code [CA3866]
Failure Code [CA3868]
Failure Code [CA4151]
Failure Code [CA4155]
Failure Code [CA4156]
Failure Code [CA4157]
Failure Code [CA4158]
Failure Code [CA4161]
Failure Code [CA4162]
Failure Code [CA4163]
Failure Code [CA4168]
Failure Code [CA4169]
Failure Code [CA4171]
Failure Code [CA4249]
Failure Code [CA4251]
Failure Code [CA4259]
Failure Code [CA4264]
Failure Code [CA4266]
Failure Code [CA4267]
Failure Code [CA4277]
Failure Code [CA4459]
Failure Code [CA4461]
Failure Code [CA4731]
Failure Code [CA4739]
Failure Code [CA4768]
Failure Code [CA4769]
Failure Code [CA4842]
Failure Code [CA5115]
Failure Code [CA5179]
Failure Code [CA5181]
Failure Code [CA5271]
Failure Code [CA5272]
Failure Code [CA5383]
Failure Code [CA5631]
Failure Code [CA5632]
Failure Code [CA5655]
Failure Code [CA5689]
Failure Code [CA5715]
Failure Code [CA5838]
Failure Code [CA5864]
Failure Code [CA5865]
Failure Code [CA5938]
Failure Code [CA6256]
Failure Code [CA6257]
Failure Code [CA6266]
Failure Code [CA6475]
Failure Code [CA6476]
Failure Code [CA6477]
Failure Code [CA6478]
Failure Code [CA6479]
Failure Code [CA6481]
Failure Code [CA6512]
Failure Code [CA6524]
Failure Code [CA6525]
Failure Code [CA6526]
Failure Code [CA6537]
Failure Code [CA6556]
Failure Code [CA6557]
Failure Code [CA6595]
Failure Code [CA6619]
Failure Code [CA6654]
Failure Code [CA6726]
Failure Code [CA6887]
Failure Code [CA6891]
Failure Code [CA7326]
Failure Code [CA7453]
Failure Code [CA7454]
Failure Code [CA7681]
Failure Code [CA7797]
Failure Code [CA7798]
Failure Code [CA7822]
Failure Code [CA7869]
Failure Code [CA8526]
Failure Code [D110KB]
Failure Code [D150KA]
Failure Code [D150KB]
Failure Code [D150KY]
Failure Code [D152KA]
Failure Code [D152KY]
Failure Code [D160KA]
Failure Code [D160KB]
Failure Code [D160KY]
Failure Code [D191KA]
Failure Code [D191KB]
Failure Code [D191KY]
Failure Code [D192KA]
Failure Code [D192KB]
Failure Code [D192KY]
Failure Code [D19HKA]
Failure Code [D19HKB]
Failure Code [D19HKY]
Failure Code [D19JKZ]
Failure Code [D1EDKB]
Failure Code [D1EDKY]
Failure Code [D201QC]
Failure Code [D524KL]
Failure Code [D524KU]
Failure Code [D525KL]
Failure Code [D525KN]
Failure Code [D526KN]
Failure Code [D528KN]
Failure Code [D528KP]
Failure Code [D52DKN]
Failure Code [D52DKP]
Failure Code [D52EKN]
Failure Code [D52FKN]
Failure Code [D52GKN]
Failure Code [D52HKN]
Failure Code [D52JKN]
Failure Code [D52KKN]
Failure Code [D52LKN]
Failure Code [D52PKX]
Failure Code [D52QKR]
Failure Code [D52TKX]
Failure Code [D52UKX]
Failure Code [D52VKN]
Failure Code [D52XKB]
Failure Code [D52YKB]
Failure Code [D52ZKR]
Failure Code [D52ZKT]
Failure Code [D52ZLA]
Failure Code [D5ZHKA]
Failure Code [D5ZHKB]
Failure Code [D5ZHKZ]
Failure Code [D5ZHL6]
Failure Code [D811MC]
Failure Code [D862KA]
Failure Code [D8ALKA]
Failure Code [D8ALKB]
Failure Code [D8G1KT]
Failure Code [D8G1XZ]
Failure Code [D8GCKR]
Failure Code [D8GDKA]
Failure Code [D8GDKB]
Failure Code [D8GEKB]
Failure Code [D8GEKY]
Failure Code [D8GPKR]
Failure Code [D8N1MA]
Failure Code [D8N2MA]
Failure Code [DAF0KT]
Failure Code [DAF0MB]
Failure Code [DAF0MC]
Failure Code [DAF3KK]
Failure Code [DAF9KQ]
Failure Code [DAFDKB]
Failure Code [DAFEKB]
Failure Code [DAFEKY]
Failure Code [DAFGMC]
Failure Code [DAFLKA]
Failure Code [DAFLKB]
Failure Code [DAFMKR]
Failure Code [DAFPKR]
Failure Code [DAFRMA]
Failure Code [DAFUKA]
Failure Code [DAFUKB]
Failure Code [DAFUKY]
Failure Code [DAQ0KK]
Failure Code [DAQ0KT]
Failure Code [DAQ0MC]
Failure Code [DAQ1KA]
Failure Code [DAQ2KK]
Failure Code [DAQ2KT]
Failure Code [DAQ9KQ]
Failure Code [DAQCMA]
Failure Code [DAQDMA]
Failure Code [DAQEMA]
Failure Code [DAQFMA]
Failure Code [DAQHMA]
Failure Code [DAQJMA]
Failure Code [DAQKKA]
Failure Code [DAQLKA]
Failure Code [DAQLKB]
Failure Code [DAQMKR]
Failure Code [DAQRKR]
Failure Code [DAQRMA]
Failure Code [DAQSKR]
Failure Code [DASRKR]
Failure Code [DAZ9KQ]
Failure Code [DAZQKR]
Failure Code [DB2QKR]
Failure Code [DB90KK]
Failure Code [DB90KT]
Failure Code [DB90MC]
Failure Code [DB91KA]
Failure Code [DB92KK]
Failure Code [DB92KT]
Failure Code [DB94KB]
Failure Code [DB95KX]
Failure Code [DB96KX]
Failure Code [DB97KX]
Failure Code [DB98KX]
Failure Code [DB99KQ]
Failure Code [DB9CMA]
Failure Code [DB9DMA]
Failure Code [DB9EMA]
Failure Code [DB9FMA]
Failure Code [DB9GMA]
Failure Code [DB9HMA]
Failure Code [DB9JMA]
Failure Code [DB9KKA]
Failure Code [DB9LKA]
Failure Code [DB9LKB]
Failure Code [DB9MKR]
Failure Code [DB9RKR]
Failure Code [DB9RMA]
Failure Code [DB9SKR]
Failure Code [DBE5KX]
Failure Code [DBE6KX]
Failure Code [DBE7KX]
Failure Code [DBKEKR]
Failure Code [DBP0KM]
Failure Code [DBP0KT]
Failure Code [DBPWKR]
Failure Code [DD1LKA]
Failure Code [DD1LKB]
Failure Code [DD61KA]
Failure Code [DD61KB]
Failure Code [DDAAL6] (Machine without Emergency Engine Stop Switch)
Failure Code [DDAAL6] (Machine with Emergency Engine Stop Switch)
Failure Code [DDB6KA]
Failure Code [DDB6KB]
Failure Code [DDBAKA]
Failure Code [DDBAKB]
Failure Code [DDBBKA]
Failure Code [DDBBKB]
Failure Code [DDBCKA]
Failure Code [DDBCKB]
Failure Code [DDBCL4]
Failure Code [DDBCQC]
Failure Code [DDBDKA]
Failure Code [DDBDKB]
Failure Code [DDG1KB]
Failure Code [DDG2KB]
Failure Code [DDK3KA]
Failure Code [DDK3KB]
Failure Code [DDK4KA]
Failure Code [DDK4KB]
Failure Code [DDK5LD]
Failure Code [DDK6KA]
Failure Code [DDK6KB]
Failure Code [DDNRKA]
Failure Code [DDNRKY]
Failure Code [DDUAKR]
Failure Code [DDUBKR]
Failure Code [DDUCKR]
Failure Code [DF50KA]
Failure Code [DF50KY]
Failure Code [DGF1KA]
Failure Code [DGF1KB]
Failure Code [DGH2KA]
Failure Code [DGH2KX]
Failure Code [DGH4KA]
Failure Code [DGH4KX]
Failure Code [DGR2KB]
Failure Code [DGR2KZ]
Failure Code [DGR4KB]
Failure Code [DGR4KZ]
Failure Code [DGRFKA]
Failure Code [DGRFKY]
Failure Code [DH1GKA]
Failure Code [DH1GKY]
Failure Code [DH1HKA]
Failure Code [DH1HKY]
Failure Code [DH1JKA]
Failure Code [DH1JL8]
Failure Code [DH21KA]
Failure Code [DH21KB]
Failure Code [DHHBKA]
Failure Code [DHHBKY]
Failure Code [DHHCKA]
Failure Code [DHHCKY]
Failure Code [DHPCKA]
Failure Code [DHPCKY]
Failure Code [DHPDKA]
Failure Code [DHPDKY]
Failure Code [DHT8KA]
Failure Code [DHT8KB]
Failure Code [DHT8ZG]
Failure Code [DHTCL6]
Failure Code [DHTEKA]
Failure Code [DHTEKY]
Failure Code [DHUCKA]
Failure Code [DHUCKY]
Failure Code [DHUDKA]
Failure Code [DHUDKB]
Failure Code [DHUJKA]
Failure Code [DHUJKY]
Failure Code [DHYEKA]
Failure Code [DHYEKY]
Failure Code [DHZ1KX]
Failure Code [DJF1KA]
Failure Code [DK38KA]
Failure Code [DK38KY]
Failure Code [DK39KA]
Failure Code [DK39KY]
Failure Code [DK3AKA]
Failure Code [DK3AMA]
Failure Code [DK3BKA]
Failure Code [DK3BMA]
Failure Code [DK3CKA]
Failure Code [DK3CKM]
Failure Code [DK3CL8]
Failure Code [DK3CMA]
Failure Code [DK3DKA]
Failure Code [DK3DMA]
Failure Code [DK3EKA]
Failure Code [DK3EKM]
Failure Code [DK3EL8]
Failure Code [DK3EMA]
Failure Code [DK3FKA]
Failure Code [DK3FMA]
Failure Code [DK3GKA]
Failure Code [DK3GL8]
Failure Code [DK3HL8]
Failure Code [DK3JL8]
Failure Code [DK3KL3]
Failure Code [DK3KL8]
Failure Code [DK55KA]
Failure Code [DK55KY]
Failure Code [DK55L5]
Failure Code [DK59KA]
Failure Code [DK59KY]
Failure Code [DK59L8]
Failure Code [DK5AKA]
Failure Code [DK5AKY]
Failure Code [DK5BKA]
Failure Code [DK5BKY]
Failure Code [DK5BL8]
Failure Code [DK5CKA]
Failure Code [DK5CKY]
Failure Code [DK5DKA]
Failure Code [DK5DKY]
Failure Code [DK5DL8]
Failure Code [DK5EKA]
Failure Code [DK5EKY]
Failure Code [DK60KR]
Failure Code [DK60KX]
Failure Code [DK70KA]
Failure Code [DK70KY]
Failure Code [DK71KA]
Failure Code [DK71KY]
Failure Code [DK72KA]
Failure Code [DK72L8]
Failure Code [DKA0KA]
Failure Code [DKA0KY]
Failure Code [DKA0L0]
Failure Code [DKA1KA]
Failure Code [DKA1KY]
Failure Code [DKH7KA]
Failure Code [DKH7MA]
Failure Code [DKR0KA]
Failure Code [DKR0KB]
Failure Code [DKR1KA]
Failure Code [DKR1KB]
Failure Code [DKR2KX]
Failure Code [DKR2NX]
Failure Code [DKR5KA]
Failure Code [DKR5KB]
Failure Code [DLF1KA]
Failure Code [DLF1LC]
Failure Code [DLM0KA]
Failure Code [DLM0LC]
Failure Code [DLM3KA]
Failure Code [DLM3LC]
Failure Code [DLT3KX]
Failure Code [DLT4KX]
Failure Code [DLT4L0]
Failure Code [DLT4L8]
Failure Code [DLT4LC]
Failure Code [DLT6LC]
Failure Code [DPQ2KR]
Failure Code [DQA1KB]
Failure Code [DQA1KM]
Failure Code [DQA1KR]
Failure Code [DQA1KT]
Failure Code [DQA1KY]
Failure Code [DQA2KM]
Failure Code [DQA2KR]
Failure Code [DQA2KT]
Failure Code [DQA3KB]
Failure Code [DQA3KY]
Failure Code [DR12KA]
Failure Code [DR12KB]
Failure Code [DR12KK]
Failure Code [DR12KR]
Failure Code [DR12KY]
Failure Code [DUMBKA]
Failure Code [DUMBKB]
Failure Code [DV00KB]
Failure Code [DV01KB]
Failure Code [DV01KY]
Failure Code [DV20KB]
Failure Code [DV20KY]
Failure Code [DV50KA]
Failure Code [DV50KB]
Failure Code [DV50KY]
Failure Code [DW4BKA]
Failure Code [DW4BKB]
Failure Code [DW4BKY]
Failure Code [DW4PKA]
Failure Code [DW4PKB]
Failure Code [DW4PKY]
Failure Code [DW4QKA]
Failure Code [DW4QKB]
Failure Code [DW4QKY]
Failure Code [DW4RKA]
Failure Code [DW4RKB]
Failure Code [DW4RKY]
Failure Code [DW4SKA]
Failure Code [DW4SKB]
Failure Code [DW4SKY]
Failure Code [DW7BKA]
Failure Code [DW7BKB]
Failure Code [DW7BKY]
Failure Code [DW9CKA]
Failure Code [DW9CKB]
Failure Code [DW9CKY]
Failure Code [DW9CZG]
Failure Code [DWM1KA]
Failure Code [DWM1KB]
Failure Code [DWM1KY]
Failure Code [DWPWKA]
Failure Code [DWPWKB]
Failure Code [DWPWKY]
Failure Code [DWRBKA]
Failure Code [DWRBKB]
Failure Code [DWRBKY]
Failure Code [DWRCKA]
Failure Code [DWRCKB]
Failure Code [DWRCKY]
Failure Code [DWRDKA]
Failure Code [DWRDKB]
Failure Code [DWRDKY]
Failure Code [DWREKA]
Failure Code [DWREKB]
Failure Code [DWREKY]
Failure Code [DWRFKA]
Failure Code [DWRFKB]
Failure Code [DWRFKY]
Failure Code [DWRGKA]
Failure Code [DWRGKB]
Failure Code [DWRGKY]
Failure Code [DWRHKA]
Failure Code [DWRHKB]
Failure Code [DWRHKY]
Failure Code [DWRJKA]
Failure Code [DWRJKB]
Failure Code [DWRJKY]
Failure Code [DWRKKA]
Failure Code [DWRKKB]
Failure Code [DWRKKY]
Failure Code [DWRLKA]
Failure Code [DWRLKB]
Failure Code [DWRLKY]
Failure Code [DX16KA]
Failure Code [DX16KB]
Failure Code [DX16KY]
Failure Code [DX35KA]
Failure Code [DX35KB]
Failure Code [DX35KY]
Failure Code [DXA1KA]
Failure Code [DXA1KB]
Failure Code [DXA1KY]
Failure Code [DXANKA]
Failure Code [DXANKB]
Failure Code [DXANKY]
Failure Code [DXFAKA]
Failure Code [DXFAKB]
Failure Code [DXFAKY]
Failure Code [DXFBKA]
Failure Code [DXFBKB]
Failure Code [DXFBKY]
Failure Code [DXFCKA]
Failure Code [DXFCKB]
Failure Code [DXFCKY]
Failure Code [DXFDKA]
Failure Code [DXFDKB]
Failure Code [DXFDKY]
Failure Code [DXHJKA]
Failure Code [DXHJKB]
Failure Code [DXHJKY]
Failure Code [DXHKKA]
Failure Code [DXHKKB]
Failure Code [DXHKKY]
Failure Code [DY26KB]
Failure Code [DY26KY]
Failure Code [DY30MA]
Failure Code [DY30MC]
Failure Code [DY30ME]
Failure Code [E111KT]
Failure Code [E111MC]
Failure Code [F313KA]
Failure Code [F313KB]
Failure Code [F314KA]
Failure Code [F314KB]
Failure Code [F315KB]
Failure Code [F315KY]
Failure Code [F316KB]
Failure Code [F316KY]
Failure Code [F317KA]
Failure Code [F317KB]
Failure Code [F318KB]
Failure Code [F318KY]
Failure Code [F31AKB]
Failure Code [F31AKY]
Failure Code [F31BKB]
Failure Code [F31BKY]
Failure Code [F31CKB]
Failure Code [F31CKY]
Failure Code [F31DKB]
Failure Code [F31DKY]
Failure Code [F31EKB]
Failure Code [F31EKY]
Failure Code [FG11KA]
Failure Code [FG11KY]
Failure Code [FG12KA]
Failure Code [FG12KY]
Failure Code [FG13L0]
Failure Code [FG13MC]
Failure Code [FG15MC]
Failure Code [FG15MR]
Failure Code [FG16MC]
Failure Code [FG16MR]
Failure Code [FH11N1]
Failure Code [FH11QC]
Failure Code [FH12N1]
Failure Code [FJBAKR]
Failure Code [FL01KR]
Failure Code [FL02KR]
Failure Code [FL03KR]
Failure Code [FL04KR]
Failure Code [FL05KR]
Failure Code [FL06KR]
Failure Code [FL07KR]
Failure Code [FL08KR]
Failure Code [FL09KR]
Failure Code [FL0AKB]
Failure Code [FL0ALD]
Failure Code [FL0BKB]
Failure Code [FL0BLD]
Failure Code [FL0CLD]
Failure Code [FL0DLD]
Failure Code [FL0FLD]
Failure Code [FL0GLD]
Failure Code [FL0HLD]
Failure Code [FL0JLD]
Failure Code [FL0KLD]
Failure Code [FL0LLD]
Failure Code [FL0MLD]
Failure Code [FM10MA]
Failure Code [FM11MA]
Failure Code [FM12MA]
Failure Code [FM13MA]
Failure Code [FM14MA]
Failure Code [H2K0KA]
Failure Code [H2K0KY]
Failure Code [LA00L3]
Failure Code [M000N7]
Failure Code [M000NB]
Failure Code [M000NS]
Failure Code [M000ZG]
Failure Code [R101MA]
Failure Code [R101NS]
Failure Code [R101NU]
Failure Code [R101ZT]
Failure Code [R102MA]
Failure Code [R102ZG]
Failure Code [R103MA]
Troubleshooting of Electrical System (E-Mode)
Engine Does Not Start (Engine Does Not Crank)
Manual Preheating System Does Not Operate
Automatic Preheating System Does Not Operate
While Preheating is in Operation, Preheating Pilot Lamp Does Not Come On
LCD Unit or LED Unit on Machine Monitor Display Nothing (Machine without Emergency Engine Stop Switch)
LCD Unit and LED Unit on Machine Monitor Do Not Show Anything (Machine with Emergency Engine Stop Switch)
LCD Unit on Machine Monitor Shows Nothing, Backlight is Abnormal (Backlight Goes Off or Flickers), Screen Display is Not Correct
LED Unit Lamp on Machine Monitor is Abnormal
Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Correctly
DEF Level is Not Shown Correctly
Rearview Monitor Does Not Come On or Backlight Flickers
Rearview Monitor Images are Not Shown Clearly
Rearview Monitor Brightness Cannot be Adjusted
Night Lighting Lamp of Rearview Monitor is Abnormal
Radiator Coolant Level Caution Lamp Does Not Come On
Parking Brake Indicator Lamp Does Not Light When the Parking Brake is Set to ON (Parking) Position
When Front Brake Accumulator Oil Pressure Drops, the Brake Oil Pressure Caution Lamp Does Not Come On
When Rear Brake Accumulator Oil Pressure Drops, the Brake Oil Pressure Caution Lamp Does Not Come On
Fuel Gauge Does Not Show Normally
Indication of Hydraulic Oil Temperature Gauge Does Not Increase, or Hydraulic Oil Temperature Caution Lamp Does Not Light
Seat Belt Caution Lamp Indication is Abnormal
Alarm Buzzer Does Not Sound
Alarm Buzzer Does Not Stop
Traction Control is Not Released When One-Push Traction Control Switch is Pushed
Bucket Positioner Does Not Work When Bucket Control Switch is Pushed
Load Meter Auto Measurement Function and Empty Bucket Calibration Function Do Not Operate When Load Meter Auto Measurement Switch is Pushed
Brake Does Not Work When Parking Brake is Applied or Brake Drags in Forward or Reverse Travel When Parking Brake is Released
Flow of Loader Pump Does Not Increase from the Minimum Rate
Directional Selector (FNR) Switch Mode is Not Selected or Not Released
Parking Brake Cannot be Released or Machine Does Not Start (AFJS Specification)
Traction Control Setting Can Not Switch When Traction Control Switch is Pushed
ECSS Function Cannot be Selected or Cannot be Released
Function of Auto-Digging is Not Enabled or Disabled When Auto-Digging Switch is Pushed
Remote Boom Positioner Cannot be Set When Boom Positioner Switch is Pushed
Setting of Remote Bucket Positioner Can Not Change When Bucket Positioner Switch is Pushed
Horn Does Not Operate (Steering Wheel Specification)
Horn Does Not Operate (AFJS Specification)
Horn Does Not Stop (Steering Wheel Specification)
Horn Does Not Stop (AFJS Specification)
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On (Steering Wheel Specification)
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On (AFJS Specification)
Clearance Lamp and Tail Lamp Do Not Come on or Go off (Steering Wheel Specification)
Clearance Lamp and Tail Lamp Do Not Come On or Go Off (AFJS Specification)
Low Beam and High Beam of Headlamp Do Not Come On or Go Off (Steering Wheel Specification)
Both High and Low Beams of Headlamp Do Not Come On or Go Off (AFJS Specification)
Low Beam of Headlamp Does Not Come On or Go Off (Steering Wheel Specification)
Low Beam of Headlamp Does Not Come On or Go Off (AFJS Specification)
High Beam of Headlamp Does Not Come On or Go Off (Steering Wheel Specification)
High Beam of Headlamp Does Not Come On or Go Off (AFJS Specification)
Front Working Lamp Does Not Come On or Go Off
Rear Working Lamp Does Not Come On or Go Off
Turn Signal Lamps and Hazard Lamp Do Not Come On or Go Off (Steering Wheel Specification)
All of Turn Signal Lamps and Hazard Lamps Do Not Come On or Go Off (Steering Wheel Specification for EU and Turkey)
All of Turn Signal Lamps and Hazard Lamps Do Not Come On or Go Off (AFJS Specification)
Turn Signal Lamps Do Not Come On or Go Off (Steering Wheel Specification)
Turn Signal Lamp Does Not Come On or Go Off (Steering Wheel Specification for EU and Turkey)
Turn Signal Lamp Does Not Come On or Go Off (AFJS Specification)
Hazard Lamp Does Not Come On or Go Off (Steering Wheel Specification)
Hazard Lamp Does Not Come On or Go Off (Steering Wheel Specification for EU and Turkey)
Hazard Lamp Does Not Come On or Go Off (AFJS Specification)
Brake Lamp Does Not Light or Stays Lighted
Backup Lamp Does Not Come on or Does Not Go off
Backup Buzzer Does Not Sound or Continues to Sound　
Front Wiper Does Not Operate (Steering Wheel Specification)
Front Wiper Does Not Operate (AFJS Specification)
Front Wiper Does Not Operate When Front Wiper and Window Washer Switch (AFJS) is Pushed (AFJS Specification)
Rear Wiper Does Not Operate (Steering Wheel Specification)
Rear Wiper Does Not Operate (AFJS Specification)
Fuel Feed Pump Does Not Operate or Stop Automatically
Fan Does Not Rotate in Reverse
Fan Remains Rotated in Reverse
Window Washer Does Not Operate
Front Window Washer Does Not Operate When Front Wiper and Window Washer Switch (AFJS) is Held Down (AFJS Specification)
KOMTRAX System Does Not Operate Correctly
Auto-Greasing Pump Display Shows [FCS]
Auto-Greasing Pump Display Shows [FLL]
Auto-Greasing System Does Not Operate or Stop
Angle of Rear View Mirror Can Not be Adjusted When Electric Mirror Angle Adjustment Switch is Operated
Heater Mirror Does Not Work or Turn OFF
Rear Heated Wire Glass Does Not Work or Turn OFF
Energized Tiltable Engine Hood Does Not Open/Close
Command Selector Operation Does Not Work
Air Conditioner Panel Operation Does Not Work
Travel Speed Control Dial and Travel Speed Control Dial Gauge on Machine Monitor Do Not Agree
Keypad Back Light and Pilot Lamp Do Not Dim When Monitor Brightness Selector Switch is at the Night Mode
Back Light of Air Conditioner Panel Does Not Dim When Monitor Brightness Selector Switch is at the Night Mode
Command Selector Back Light and Pilot Lamp Do Not Dim When Monitor Brightness Selector Switch is at the Night Mode
Seat Belt Reminder Revolving Lamp Does Not Come on or Stays on
Remote Open Door Does Not Operate or Remote Open Door Indicator is Not Shown Correctly
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
Information Shown in Troubleshooting Table (H-Mode)
Failure Mode and Cause Table
Machine Does Not Move, or Travel Speed is Slow
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 0 to 1 km/h (Does Not Move), Reverse Travel Speed 0 to 1 km/h (Does Not Move))
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 0 to 1 km/h (Does Not Move), Reverse Travel Speed 1 to 9km/h)
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 0 to 1 km/h (Does Not Move), Reverse Travel Speed 9 to 26km/h)
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 0 to 1 km/h (Does Not Move), Reverse Travel Speed 26 km/h or More (Reverse Travel is Correct))
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 1 to 7 km/h, Reverse Travel Speed 0 to 1 km/h (Does Not Move))
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 1 to 7 km/h, Reverse Travel Speed 1 to 9km/h)
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 1 to 7 km/h, Reverse Travel Speed 9 to 26 km/h)
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 1 to 7 km/h, Reverse Travel Speed 26 km/h or More (Reverse Travel is Correct))
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 7 to 14 km/h, Reverse Travel Speed 0 to 1 km/h (Does Not Move))
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 7 to 14 km/h, Reverse Travel Speed 1 to 9 km/h)
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 7 to 14 km/h, Reverse Travel Speed 9 to 26 km/h)
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 7 to 14 km/h, Reverse Travel Speed 26 km/h or More (Reverse Travel is Correct))
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 14 to 36 km/h, Reverse Travel Speed 0 to 1 km/h (Does Not Move))
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 14 to 36 km/h, Reverse Travel Speed 1 to 9 km/h)
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 14 to 36 km/h, Reverse Travel Speed 9 to 26 km/h)
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 14 to 36 km/h, Reverse Travel Speed 26 km/h or More (Reverse Travel is Correct))
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 36 km/h or More (Forward Travel is Correct), Reverse Travel Speed 0 to 1 km/h (Does Not Move))
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 36 km/h or More (Forward Travel is Correct), Reverse Travel Speed 1 to 9 km/h)
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 36 km/h or More (Forward Travel is Correct), Reverse Travel Speed 9 to 26 km/h)
Not Sufficient Drawbar Pull
Rim Pull is Weak (Only Immediately After the Machine Goes Into the Objective Material)
Not Sufficient Drawbar Pull (Only When Work Equipment is in Operation)
Not Sufficient Drawbar Pull (Only When You Increase Travel Speed, Travel Uphill at 0 to 7 km/h, or When You Dig)
Not Sufficient Drawbar Pull (Only When You Increase Travel Speed, Travel Uphill at 7 to 14 km/h (0 to 7 km/h is Correct))
Strong Shocks are Made When You Start Machine or Shift Gears
Strong Shocks are Made When Machine Moves Off and Do the Gear Shift (Only When Machine Moves Off)
Strong Shocks are Made at Move Off and Gear Shift (at All Gear Shift)
Strong Shocks are Made at Move Off and Gear Shift (Specified Gear Shift)
No Shock is Made at Move Off and Gear Shift, but Time Lag is Large
Engine Speed Drops Largely
Engine Speed Decreases Largely (Only Immediately After Machine Goes in Objective Material)
Engine Speed Drops Largely (Only When Work Equipment is in Operation)
Engine Speed Decreases Largely (Other Than When Immediately After You Thrust Into Object or When Work Equipment is in Operation)
The Braking Force of the Engine Brake is Not Sufficient (Braking Force is Weak at Downhill Travel, or a Time Lag Occurs at Directional Selection Operation)
The Braking Force of the Engine Brake is Not Sufficient (Braking Force is Weak at Downhill Travel, or a Time Lag Occurs at Directional Selection Operation) (Only When the Travel Speed is Between 0 and 7 km/h or Between 14 and 38 km/h)
The Braking Force of the Engine Brake is Not Sufficient (Braking Force is Weak at Downhill Travel, or a Time Lag Occurs at Directional Selection Operation) (Only When the Travel Speed is Between 7 and 14 km/h)
The Braking Force of the Engine Brake is Not Sufficient (Braking Force is Weak at Downhill Travel, or Time Lag Occurs at Directional Selection Operation) (Regardless of Travel Speed)
Machine Does Not Turn (For Steering Wheel Spec)
Machine Does Not Turn (AFJS Specification)
Turning Response is Unsatisfactory (For Steering Wheel Spec)
Turning Response is Unsatisfactory (AFJS Specification)
Steering Wheel is Heavy to Operate
Operating Force of AFJS Lever is Heavy (AFJS Specification)
Machine Sways or Large Shocks are Made While Machine Turns (For Steering Wheel Spec)
Machine Sways or Large Shocks are Made While Machine Turns (AFJS Specification)
Turning Radius is Different Between Right and Left Turns (Steering Wheel Specification)
Turning Radius is Different Between Right and Left Turns (AFJS Specification)
Steering Speed is Low (AFJS Specification)
Steering Speed is High (AFJS Specification)
Steering Force is Low (AFJS Specification)
Wheel Brakes Do Not Operate or are Weak
Wheel Brakes are Not Released or Drag
Parking Brake Does Not Work or It is Weak
Parking Brake is Not Released or Drags
Boom Does Not Rise
Boom Moves Slow or Boom Lacks Lifting Force
Rising Boom Slows Down at Some Height
Lift Cylinders Can Not Hold Bucket on Ground
Hydraulic Drift of Boom is Large
Boom Moves Up and Down During Operation
Bucket Does Not Tilt Back
Bucket Moves Slow or Lacks Tilt-Back Force
Bucket Slows Down During Tilt Back or Dump Operation
Bucket Cylinder Does Not Hold Bucket on Ground
Hydraulic Drift of Bucket is Large
Bucket Tilts Back and Forth While You Carry Load (Work Equipment Valve in Hold)
Boom and Bucket Control Levers Do Not Move Smoothly and are Heavy to Move
When Operating Work Equipment Engine Speed Drops Largely or Engine Stops
Large Shocks are Made When Work Equipment Starts to Move and Stops
When Some Work Equipment Stalls Hydraulically, Other Work Equipment Moves
ECSS Does Not Operate and Machine Pitches and Bounces
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)
Unusual Noise is Heard from Around Fan
Floor Vibration or Noise in Cab Increased (Boxy Noise is Heard)
Troubleshooting of Engine (S-Mode)
Information Shown in Troubleshooting Table (S-Mode)
Engine Does Not Crank When Starting Switch is Turned to START Position
Engine Cranks but No Exhaust Smoke Comes Out
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)
Engine Startability is Unsatisfactory
Engine Does Not Pick Up Smoothly
Engine Stops During Operation
Engine Runs Rough or is Not Stable
Engine Lacks Power
KDPF Becomes Clogged in a Short Time
Engine Oil Consumption is Excessive
Engine Oil Becomes Dirty Quickly
Fuel Consumption is Excessive
Oil is in Coolant (or Coolant Spurts Back or Coolant)
Engine Oil Pressure Drops
Fuel Mixes Into Engine Oil
Water Mixes Into Engine Oil (Milky)
Coolant Temperature Increases Too High (Overheating)
Unusual Noise is Heard
Vibration is Excessive
Air Cannot be Bled from Fuel Circuit
Active Regeneration is Done Frequently
Active Regeneration Continues Long
White Smoke is Exhausted During Active Regeneration
DEF Consumption is High
There is Unusual Smell (Irritating Odor)
Foreign Materials Enter DEF (DEF Increases)
Pressure in Crankcase is High
Troubleshooting for Auto-Greasing System
Outline of Failure Display
Troubleshooting When Error Message [FPS] is Shown
Troubleshooting for Auto-Greasing Pump
Replace Pump Element
Troubleshooting for Grease Supply System
Replace Auto-Greasing Controller
Assembly procedure when disassembled in troubleshooting
50 Disassembly and Assembly
Table of Contents
Precautions Before Work
Related Information on Disassembly and Assembly
How to read this manual
Symbol List
Coating Materials List
Special Tool List
Sketches of Special Tools
Prepare
Drain and Add Coolant
Drain and Add Hydraulic Oil
Drain and Add Fuel
Collect and Refill Refrigerant
Engine and Cooling System
Remove and Install Supply Pump Assembly
Remove and Install Injector Assembly
Remove and Install Fuel Doser Assembly
Remove and Install Cylinder Head Assembly
Remove and Install Starting Motor Assembly
Remove and Install Alternator Belt
Remove and Install Auto-Tensioner
Remove and Install Expansion Tank Assembly
Remove and Install Radiator Assembly
Remove and Install Cooling Fan and Fan Motor Assembly
Remove and Install Hydraulic Oil Cooler Assembly
Remove and Install Aftercooler Assembly
Remove and Install Power Train Oil Cooler Assembly
Remove and Install Engine and Transmission Assembly
Disconnect and Connect Engine and Transmission Assembly
Remove and Install Engine Front Oil Seal
Remove and Install Engine Rear Oil Seal
Remove and Install Engine Hood Assembly
Remove and Install Fuel Tank Assembly
Remove and Install DEF Tank Assembly
Remove and Install DEF Tank Sensor Flange Assembly
Remove and Install DEF Tank Sensor
Remove and Install DEF Tank Strainer
Remove and Install KDPF Assembly
Disassemble and Assemble KDPF Assembly
Remove and Install SCR Assembly
Remove and Install KDPF and SCR Assembly
Remove and Install Bellows Pipe Assembly
Remove and Install DEF Mixing Device
Remove and Install DEF Injector
Remove and Install DEF Pump
Remove and Install DEF Hose
Remove and Install Air Cleaner Assembly
Remove and Install Air Conditioner Compressor Assembly
Remove and Install Air Conditioner Condenser Assembly
Power Train
Remove and Install Damper Assembly
Disassemble and Assemble Damper Assembly
Remove and Install HST Motor Assembly
Disassemble and Assemble Transmission Assembly
Disassemble and Assemble Transmission Clutch Pack Assembly
Remove and Install Front Axle Assembly
Remove and Install Rear Axle Assembly
Remove and Install Drive Shaft Assembly
Disassemble and Assemble Axle Housing Assembly (WA475-11 Standard Axle)
Disassemble and Assemble Axle Housing Assembly (WA475-11 Reinforced Axle, WA485-11)
Disassemble and Assemble Differential Assembly
Steering System
Remove and Install Steering Valve Assembly
Remove and Install Steering Valve Assembly (AFJS Specifications)
Remove and Install Orbitrol Valve Assembly
Brake System
Remove and Install Parking Brake Disc and Plate
Undercarriage and Frame
Remove and Install Center Hinge Pin
Remove and Install Counterweight Assembly (WA475-11)
Remove and Install Counterweight Assembly (WA485-11)
Remove and Install Full-Length Fender Assembly
Hydraulic System
Remove and Install Hydraulic Tank Assembly
Remove and Install Work Equipment Pump and Power Train Pump Assembly
Remove and Install Steering Pump, Cooling Fan Pump, and HST Charge Pump Assembly
Remove and Install Control Valve Assembly
Work Equipment
Remove and Install Work Equipment Assembly
Disassemble and Assemble Steering Cylinder Assembly
Disassemble and Assemble Lift Cylinder Assembly
Disassemble and Assemble Bucket Cylinder Assembly
CAB Related Parts
Remove and Install Operator Cab Assembly
Remove and Install Operator Cab Door
Remove and Install Operator Cab Glass (Adhered Glass)
Remove and Install Air Conditioner Unit Assembly
Remove and Install Air Conditioner Blower Assembly
Remove and Install Operator Seat Assembly
Remove and Install Operator Seat Assembly (AFJS Specification)
Remove and Install Seat Belt
Remove and Install AFJS Lever
Remove and Install AFJS Electric Lever
Electrical System
Remove and Install Engine Controller Assembly
Remove and Install Work Equipment Controller Assembly
Remove and Install Transmission Controller Assembly
Remove and Install Monitor Controller Assembly
Remove and Install Machine Monitor Assembly
Remove and Install KomVision Controller
Remove and Install Starter Signal Unit
Remove and Install Intake Manifold Pressure and Temperature Sensor
Remove and Install KDPF Temperature Sensor
Remove and Install KDPF Differential Pressure Sensor
Remove and Install SCR Outlet NOx Sensor
Remove and Install Turbo Outlet NOx Sensor
Remove and Install Gateway Function Controller Assembly
Remove and Install Communication Terminal
Remove and Install Radar
Remove and Install Articulate Angle Sensor
60 Maintenance Standard
Table of Contents
Engine and Cooling System
Maintenance Standard for Engine Mount
Maintenance Standard for Brake and Cooling Fan Pump
Maintenance Standard for Cooling Fan Motor
Power Train
Maintenance Standard for Drive Shaft
Maintenance Standard for Transmission
Maintenance Standard for Transmission Control Valve
Maintenance Standard for ECMV
Maintenance Standard for Valve Assembly (Main Relief, Power Train Oil Cooler Relief)
Maintenance Standard for Front Axle
Maintenance Standard for Rear Axle
Maintenance Standard for Front Conventional Differential
Maintenance Standard for Rear Conventional Differential
Maintenance Standard for Front Limited Slip Differential
Maintenance Standard for Rear Limited Slip Differential
Maintenance Standard for Front Final Drive
Maintenance Standard for Rear Final Drive
Steering System
Maintenance Standard for Steering Column
Maintenance Standard for Steering System (AFJS Specification)
Maintenance Standard for Steering Pump
Maintenance Standard for Steering Valve (For Steering Wheel Spec)
Maintenance Standard for Steering Cylinder
Maintenance Standard for Secondary Steering Pump
Brake System
Maintenance Standard for Charge Valve
Maintenance Standard for Brake Circuit Accumulator
Maintenance Standard for Slack Adjuster
Maintenance Standard for Front Brake
Maintenance Standard for Rear Brake
Maintenance Standard for Parking Brake
Maintenance Standard for Parking Brake Solenoid Valve
Undercarriage and Frame
Maintenance Standard for Frame, Axle Mount and Center Hinge Pin
Hydraulic System
Maintenance Standard for Hydraulic Tank
Maintenance Standard for Work Equipment Pump
Maintenance Standard for Power Train Charge Pump and Power Train Lubrication Pump
Maintenance Standard for HST Charge Pump
Maintenance Standard for HST Valve
Maintenance Standard for Control Valve
Maintenance Standard for Work Equipment Lock Solenoid Valve
Work Equipment
Maintenance Standard for Work Equipment Linkage
Maintenance Standard for Bucket
Maintenance Standard for Lift Cylinder
Maintenance Standard for Bucket Cylinder
80 Appendix
Table of Contents
Precautions Before Work
Air Conditioner System
Precautions for Refrigerant
Air Conditioner Component
Specifications of Air Conditioner
Structure and Function of Refrigeration Cycle
Outline of Refrigeration Cycle
Component Parts of Air Conditioner System
Air Conditioner Unit
Component Parts of Air Conditioner Unit
Air Conditioner Controller
Compressor
Condenser
Receiver Drier
Air Conditioner Related Sensors
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner
Circuit Diagram and Configuration of Connector Pins of Air Conditioner
System Diagram of Air Conditioner
Input and Output Signals of Air Conditioner Controller
Locations of Air Conditioner Parts and Layout of Connectors
Examine Air Conditioner with Self-Diagnosis Function
How to See Electrical System Abnormality Record by SDT
Examine Temperature Control Function
How to Examine Temperature Control Function
Examine Vent (Mode) Changeover
How to Examine Vent (Mode) Changeover
Examine Fresh/Recirc Air Changeover
How to Examine Fresh/Recirc Air Changeover
Examine Evaporator Temperature Sensor
Examine Relay
How to Examine Relay
Air Conditioner Troubleshooting Chart 1
Air Conditioner Troubleshooting Chart 2
Information Shown in Troubleshooting Table
Failure Code [879AKA]
Failure Code [879AKB]
Failure Code [879BKA]
Failure Code [879BKB]
Failure Code [879CKA]
Failure Code [879CKB]
Failure Code [879DKZ]
Failure Code [879EMC]
Failure Code [879FMC]
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
Troubleshooting for Fresh/Recirc Air Changeover
Troubleshooting by Gauge Pressure
Connect Service Tool
How to Connect Service Tool
Precautions for Disconnection and Connection of Air Conditioner Piping
Handle Compressor Oil
90 Circuit Diagrams
Table of Contents
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Hydraulic Circuit Diagram (Steering Wheel Specification) (1/2)
Hydraulic Circuit Diagram (Steering Wheel Specification) (2/2)
Hydraulic Circuit Diagram (AFJS Specification) (1/2)
Hydraulic Circuit Diagram (AFJS Specification) (2/2)
Hydraulic Circuit Diagram (Steering Wheel Specification) (Combination of Boom RAISE, Steer Left, and Brake Operation) (1/2)
Hydraulic Circuit Diagram (Steering Wheel Specification) (Combination of Boom RAISE, Steer Left, and Brake Operation) (2/2)
Power Train Hydraulic Circuit Diagram
Hydraulic Auto-Greasing Diagram
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram
Electrical Circuit Diagram of Machine (1/10)
Electrical Circuit Diagram of Machine (2/10)
Electrical Circuit Diagram of Machine (3/10)
Electrical Circuit Diagram of Machine (4/10)
Electrical Circuit Diagram of Machine (5/10)
Electrical Circuit Diagram of Machine (6/10)
Electrical Circuit Diagram of Machine (7/10)
Electrical Circuit Diagram of Machine (8/10)
Electrical Circuit Diagram of Machine (9/10)
Electrical Circuit Diagram of Machine (10/10)
Electrical Circuit Diagram of Floor (1/11)
Electrical Circuit Diagram of Floor (2/11)
Electrical Circuit Diagram of Floor (3/11)
Electrical Circuit Diagram of Floor (4/11)
Electrical Circuit Diagram of Floor (5/11)
Electrical Circuit Diagram of Floor (6/11)
Electrical Circuit Diagram of Floor (7/11)
Electrical Circuit Diagram of Floor (8/11)
Electrical Circuit Diagram of Floor (9/11)
Electrical Circuit Diagram of Floor (10/11)
Electrical Circuit Diagram of Floor (11/11)
Index