Komatsu Wheel Loader WA470 Repair Service Manuals
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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA470, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Wheel Loader WA470 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEBM027200 - Wheel Loader WA470-7 Shop Manual.pdf
CEBM027201 - Wheel Loader WA470-7 Shop Manual.pdf
CEBM030000 - Wheel Loader WA470-8 Shop Manual.pdf
GEN00122-00 - Wheel Loader WA470-7 Field Assembly Instruction.pdf
SEBM006307 - Wheel Loader WA470-3 avance Shop Manual.pdf
SEBMU4210106 - Wheel Loader WA470-1 Shop Manual.pdf
SEN06006-02 - Wheel Loader WA470-7 Shop Manual.pdf
SEN06514-08 - Wheel Loader WA470-8 Shop Manual.pdf
SMEW4700K0 - avance Loader Custom avance WA470-3 Shop Manual (Serial Number WA470-3 20001 & up).pdf
SMEW4700M0 - Wheel Loader MAX avance WA470-3 Shop Manual (Serial Number WA470H-20051 & up).pdf
TEN00091-00 - Wheel Loader GALEO WA470-5 Operation & Maintenance Manual.pdf
TEN00091-03 - Wheel Loader WA470-5 Operation & Maintenance Manual.pdf
TEN00176-04 - Wheel Loader WA470-6 Operation & Maintenance Manual.pdf
TEN00294-02 - Wheel Loader WA470-6 Operation & Maintenance Manual.pdf
TEN00339-03 - Wheel Loader WA470-6 Operation & Maintenance Manual.pdf
TEN00451-00 - Wheel Loader WA470-6 Operation & Maintenance Manual.pdf
TEN00602-01 - Wheel Loader WA470-7 Operation & Maintenance Manual.pdf
VEAM946100 - Wheel Loader WA470-6 Operation & Maintenance Manual.pdf
VEAM946102 - Wheel Loader WA470-6 Operation & Maintenance Manual.pdf
VEBM480104 - Wheel Loader WA470-3 Shop Manual (Serial Number WA470H20051 & up).pdf
CEAM009203 - Wheel Loader WA470-6 Operation & Maintenance Manual.pdf
CEAM023501 - Wheel Loader WA470-6 Operation & Maintenance Manual.pdf
CEAM026700 - Wheel Loader WA470-7 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 23,021 pages
File Format: PDF
Language: English
CEAM009203 - Wheel Loader WA470-6 Operation & Maintenance Manual....3
CEAM009203....3
INTRODUCTION....5
FOREWORD....6
SAFETY INFORMATION....7
APPROVED AND NON-APPROVED USES....8
Approved Functions....8
Non-Approved Functions....8
VISIBILITY STANDARD....9
Visibility in Immediate Area....9
12-M Radius Visibility....9
PRODUCT IDENTIFICATION....10
Machine....10
Service Meter Location....11
Directions of Machine....11
Machine Serial Number/Product Identification Number (PIN)....12
Engine Serial Number, EPA Regulations....12
SERIAL NUMBERS AND DEALER INFORMATION....13
Model: WA470-6....13
TABLE OF CONTENTS....14
SAFETY....27
SAFETY AND WARNING DECALS....28
Location of the Safety Labels....28
Safety Labels....29
GENERAL SAFETY RULES AND PRECAUTIONS....36
General Safety Rules....36
Safety at Job Site....37
Safety Features....37
Clothing and Protective Equipment....37
Keep Machine Clean....38
Fire and Explosion Prevention....38
Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid....38
Fire Caused by Accumulation of Flammable Material....39
Fire Caused by Electrical Wiring....39
Fire Caused by Piping....39
Explosion Caused by Lighting Equipment....39
Action if Fire Occurs....40
Fire Extinguisher and First Aid Kit....40
Mounting and Dismounting....41
Inside Operator’s Compartment....42
Emergency Escape from Operator’s Cab....42
Precautions When Standing Up from Operator’s Seat....43
Leaving Operator’s Compartment....44
Parking the Machine....45
Transporting the Machine....46
Precautions When Using ROPS....48
Unauthorized Modification....48
Precautions for Attachments and Options....48
Precautions When Cleaning Cab Glass....49
Asbestos Hazard Alert....49
Crush or Pinch-Point Dangers....50
Precautions for Ventilation Exhaust Gas....50
PRECAUTIONS BEFORE STARTING OPERATIONS....51
Pre-Operational Checks....51
Seat Belt Inspection....52
Ensure Good Visibility....53
Signs and Signals....53
Precaution for Warning Tag....54
Checks Before Starting Engine, Adjustments....54
Precautions When Starting....55
Precautions in Cold Areas....55
Precautions for Job Site....56
Work Site Hazards....56
Working on Loose or Unstable Ground....56
Prohibited Operations....57
Avoiding Dangerous Situations....57
Working Near High Voltage Cables....59
RULES FOR ROAD TRAVEL....60
Travel Precautions....60
Traveling on Slopes....61
Using the Brakes....62
Traveling in Reverse....62
Operating on Snow or Frozen Surfaces....63
PRECAUTIONS DURING INSPECTION AND MAINTENANCE....64
Warning Tags....64
Workplace Environment....64
Systems Equipped with ECSS....64
Equipment Storage....65
Working Under the Machine....65
Using Drop Lamps....66
Using Proper Tools....66
Keeping the Machine Clean....66
Precautions When Welding....66
Precautions When Using Hammer....67
Noise....67
Stopping Engine During Inspection and Maintenance....68
Running the Machine During Maintenance....70
Rules for Refueling the Machine....71
Cooling System Precautions....71
Window Washer Fluid....71
Battery Information....71
Precautions....71
Hazards....72
Using Booster Cables....73
Starting the Machine with Booster Cables....73
High-Pressure Precautions....74
Precautions for High-Pressure Oil....74
Safe Handling of High-Pressure Hoses....74
Precautions for High-Pressure Fuel....74
High-Temperature Precautions....75
High-Temperature Areas....75
High-Temperature Coolant....75
High-Temperature Oil....75
High Voltage....75
Accumulator and Gas Spring....76
Using Compressed Air....76
Disposal of Waste Materials....76
Inflating Tires....77
Storing Tires....77
Maintenance of Air Conditioner....78
Critical Parts....78
OPERATION....79
GENERAL VIEW....80
General View of Machine....80
General View of Controls and Gauges....81
Machine Monitor....82
Switch Panel....83
EXPLANATION OF COMPONENTS....84
Machine Monitor....84
Types of Warnings....85
Emergency Stop....85
Mistaken Operation....85
Inspection and Maintenance....85
Central Warning Lamp....85
Character Display Portion....86
Service Meter....87
Action Code Display....87
Failure Code Display....88
Filter, Oil Replacement Time Display....89
Emergency Stop Items....91
Brake Oil Pressure Caution Lamp....92
Engine Oil Pressure Caution Lamp....92
Battery Charge Circuit Caution Lamp....93
Steering Oil Pressure Caution Lamp (if equipped)....93
Caution Items....94
Brake Oil Temperature Caution Lamp....95
Torque Converter Oil Temperature Caution Lamp....95
Engine Coolant Temperature Caution Lamp....96
Hydraulic Oil Temperature Caution Lamp....96
Fuel Level Caution Lamp....96
Inspection and Maintenance Items....97
Radiator Coolant Level Caution Lamp....97
Engine Oil Level Caution Lamp....98
Battery Electrolyte Level Caution Lamp (if equipped)....98
Maintenance Caution Lamp....98
Air Cleaner Clogging Caution Lamp....99
Water Separator Caution Lamp....99
Transmission Oil Filter Clogging Caution Lamp....99
Pilot Display Portion....100
Parking Brake Pilot Lamp....101
Cooling Fan Reverse Rotation Pilot Lamp....101
Emergency Steering Pilot Lamp (if equipped)....101
Power Mode Pilot Lamp (P Mode)....102
Preheating Pilot Lamp....102
Semi-Auto Digging Pilot Lamp....102
Auto-Greasing Pilot Lamp (if equipped)....102
Joystick Pilot Lamp (if equipped)....102
Directional Selector Pilot Lamp (if equipped)....102
Economy Operation Display Lamp....103
Shift Indicator....103
Auto-Shift Pilot Lamp....103
Torque Converter Lockup Pilot Light (if equipped)....103
Shift Hold Pilot Lamp....104
Shift Lever Position Pilot Lamp....104
Turn Signal Pilot Lamp....104
Head Lamp High-Beam Pilot Lamp....104
Meter Display Portion....105
Torque Converter Oil Temperature Gauge....105
Engine Coolant Temperature Gauge....106
Hydraulic Oil Temperature Gauge....106
Fuel Gauge....106
Speedometer....107
Meter Display Pilot Lamp....107
OTHER FUNCTIONS OF MACHINE MONITOR....108
Overall Menu....108
Displaying Odometer....110
Resetting Filter, Oil Replacement Time....110
Entering Telephone Number....111
Selecting Language....112
Adjusting Monitor Brightness....114
Switching Travel Speed/Engine Speed Display....116
Switching Travel Speed/Engine Speed Display/Non-Display....117
SWITCHES AND CONTROLS....118
General View....118
Ignition Switch....120
Power Mode Selector Switch....120
Transmission Shift Mode Selector Switch....121
Transmission Cutoff Switch....121
Transmission Cutoff Set Switch....122
Lamp Switch....122
Turn Signal Lever....122
Dimmer Switch....123
Horn Button....123
Hazard Lamp Switch....123
Parking Brake Switch....124
Front Working Lamp Switch....124
Rear Working Lamp Switch....125
Machine Monitor Mode Selector Switch 1....125
Machine Monitor Mode Selector Switch 2....125
Kickdown Switch....126
Hold Switch....127
Front Wiper Switch....127
Rear Wiper Switch....128
Cigarette Lighter....128
Room Lamp Switch....128
Rear Heated Wire Glass Switch....128
ECSS Switch....129
Emergency Steering Switch (if equipped)....129
Cooling Fan Auto-Reverse Rotation Switch....130
Torque Converter Lockup Switch....133
CONTROL LEVERS, PEDALS....134
General View....134
Gearshift Lever....135
Directional Lever....136
Gearshift Lever Stopper....137
Work Equipment Lock Lever....137
Bucket Control Lever....138
Lift Arm Control Lever....138
Brake Pedals....139
Accelerator Pedal....139
SECURITY LOCKS AND SAFETY FEATURES....140
Steering Tilt Lock Lever....140
Frame Lock Bar....141
Cap with Lock....142
Fuel Tank Filler Port Cap....142
Hydraulic Tank Filler Port Cap....142
Backup Alarm....143
MACHINE FEATURES....144
Towing Pin....144
Grease Pump....144
Cab Door....145
Emergency Escape Right Door....145
Left Cab Door, Door Open Lock....147
Left Cab Door, Knob....148
Left Cab Door, Handle....148
Left Cab Sliding Window (Lock Release Knob)....148
Cab Wiper....149
Dust Indicator....149
Fire Extinguisher (if equipped)....149
ELECTRICAL....150
Power Outlet....150
Fuses....150
Fuse Capacity and Name of Circuit....151
Slow-Blow Fuse....152
WORK OPERATIONS....153
Walk-Around Check....153
Precautions Before Starting Work Operations....153
Check Before Starting Engine....157
Check Machine Monitor....157
Check Coolant Level, Add Coolant....158
Check Oil Level in Engine Oil Pan, Add Oil....159
Check Water Separator, Drain Water....160
Check Air Cleaner....161
Check Fuel Level, Add Fuel....162
Check Electric Wiring....163
Adjustments....165
Adjusting Seat....165
Removing or Installing Headrest....167
Adjusting Seat Belt....168
Adjusting Lever Stand....169
Adjusting Mirrors....170
Final Checks Before Starting Engine....171
Starting Engine....173
Normal Starting....173
Starting in Cold Weather....175
Automatic Warming-Up Operation....176
Operations and Checks After Starting Engine....177
Checks After Starting Engine....177
Breaking in the Machine....178
Normal Operation....178
Stopping Engine....180
Check After Stopping Engine....180
Moving the Machine (Directional, Speed), Stopping the Machine....182
Moving the Machine....182
Changing Gear Speed....185
Changing Direction....186
Stopping the Machine....188
Transmission Cutoff Function....189
Turning....191
Emergency Steering (if equipped)....192
Emergency Steering Self-Check Function....193
Operation of Work Equipment....194
Work Equipment Lock Lever....194
Lift Arm Control Lever....194
Bucket Control Lever....195
Work Possible Using Wheel Loader....197
Digging Operations....197
Loading Piled Soil or Blasted Rock....197
Digging and Loading on Level Ground....199
Leveling Operations....200
Pushing Operations....200
Load-and-Carry Operations....201
Loading Operations....202
Cross-Drive Loading....202
V-Shape Loading....202
Preparations for Loading, Gathering Rocks....203
Approaching Facing....203
Digging....204
Traveling in Reverse After Excavation....206
Approaching Dump Truck....207
Loading Dump Truck....208
Reversing Away From Dump Truck....209
Precautions During Work Operations....210
Piling Up Loads....210
Handling Blasted Rock....210
Loosened Boulders....214
Pit Excavation....214
Cutting Face Operations....214
Switching Between Forward and Reverse....214
Turning When Tires are Stationary....215
Wheel Brake Does Not Work....215
Braking Function....215
Lower the Center of Gravity when Turning....216
Permissible Water Depth....216
Driving Up or Down Slopes....216
Driving the Machine....217
Adjusting Work Equipment....218
Adjusting Boom Kickout....218
Adjusting Bucket Positioner....219
Bucket Level Indicator....220
Measuring Dump Angle....221
Measuring Bucket Dump Angle....221
Measuring Coupler Dump Angle....224
Parking the Machine....227
Checks After Completion of Operation....229
Before Stopping Engine....229
After Stopping Engine....229
Locking the Machine....230
HANDLING TIRES....232
Precautions When Handling Tires....232
Tire Pressure....233
Precautions for Using Load-and-Carry Method....234
TRANSPORTATION....235
Transportation Procedure....235
Loading and Unloading Trailers....236
Loading Machine....236
Securing Machine....237
Unloading Machine....239
LIFTING MACHINE....240
Lifting Position....240
Lifting Procedure....241
COLD WEATHER OPERATION....242
Precautions for Low Temperature....242
Fuel and Lubricants....242
Coolant....242
Battery....243
Precautions After Completion of Work....243
After Cold Weather....243
LONG-TERM STORAGE....244
Before Storage....244
During Storage....244
After Storage....244
AUTOMATIC AIR CONDITIONER....245
Control Panel....245
Main Power Switch....246
Fan Switch....246
Air Conditioner Switch....247
Auto Switch....248
Temperature Switch....248
FRESH/RECIRC Selector Switch....248
Mode Selector Switch....249
Method of Operation....250
Cooling Operation....250
Heating Operation....250
Drying-Heating and Demisting Operation....251
When Not Using the Air Conditioner Regularly....251
Precautions When Using Air Conditioner....251
Inspection and Maintenance....252
Cool Box....252
KOMTRAX....253
Basic Precautions....253
TROUBLESHOOTING....254
When Machine Runs Out of Fuel....254
Towing the Machine....254
When Engine Can Be Used....255
When Engine Cannot Be Used....255
Releasing Parking Brake....256
Emergency Travel Operation....258
If Battery is Discharged....259
Precautions....259
Removal and Installation of Battery....259
Precautions for Charging Battery....260
Starting Engine With Booster Cables....261
Precautions When Connecting or Disconnecting Booster Cable....261
Connecting Booster Cable....261
Starting Engine....262
Disconnecting Booster Cable....262
Lowering Work Equipment When Engine Has Stopped....263
Other Troubleshooting....264
Electrical System....264
Chassis....265
Engine....267
MAINTENANCE....269
GUIDES TO MAINTENANCE....270
Check Service Meter....270
Komatsu Genuine Replacement Parts....270
Komatsu Genuine Oils....270
Always Use Clean Washer Fluid....270
Always Use Clean Oil and Grease....270
Checking for Foreign Materials in Drained Oil and On Filters....270
Fuel Strainer....270
Welding Instructions....271
Do Not Drop Things Inside Machine....271
Dusty Work Sites....271
Avoid Mixing Oil....271
Locking Inspection Covers....271
Bleeding Air from Hydraulic Circuit....271
Precautions When Installing Hydraulic Hoses....272
Checks After Inspection and Maintenance....272
OUTLINES OF SERVICE....273
Handling Oil, Fuel, Coolant, and Performing Oil Clinic....273
Oil....273
Fuel....274
Coolant and Water for Dilution....274
Grease....275
Storing Oil and Fuel....275
Filters....275
Performing KOWA (Komatsu Oil Wear Analysis)....276
KOWA Analysis Items....276
Oil Sampling....276
Outline of Electric System....277
WEAR PARTS....278
Wear Parts List....278
RECOMMENDED FUEL, COOLANT, AND LUBRICANTS....279
Fuel, Coolant, and Lubricant Ambient Temperature Chart....280
Recommended Brands, Other Than Komatsu Genuine Oil....281
Biodiesel Usage....282
Biodiesel Recommendation for Komatsu Engines....282
Biodiesel Terminology....282
Certification and Standards....283
Warranty and Use of Biodiesel Fuel in Komatsu Engines....283
Requirements for Using Biodiesel Fuel in Komatsu Engines....283
Properties of Biodiesel....284
Komatsu Biodiesel Blend Specification for B5 to B20....285
Summary of Recommendations....286
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....287
Torque List....287
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....289
Safety Critical Parts List....290
MAINTENANCE SCHEDULE CHART....292
SERVICE PROCEDURE....294
Initial 250 Hours Service....294
Initial 1000 Hours Service....294
When Required....295
Clean, Replace Air Cleaner Element....295
Clean Inside of Cooling System....299
Check Transmission Oil, Add Oil....303
Check Axle Oil Level, Add Oil....305
Clean Axle Case Breather....307
Clean Air Conditioner Condenser....308
Check Window Washing Fluid Level, Add Fluid....308
Clean Radiator Fins and Cooler Fins....309
Turn, Replace Bolt-On Cutting Edge....312
Replace Bucket Teeth (if equipped)....313
Check Air Conditioner....316
Replace Slow-Blow Fuse....318
Check Function of Accumulator....319
Select Tires....320
Check Tire Pressure....321
Clean, Replace Fuel Breather Filter....322
Check Before Starting....324
Every 50 Hours Service....325
Drain Water, Sediment from Fuel Tank....325
Every 100 Hours Service....326
Lubricate Rear Axle Pivot Pin....326
Check Oil Level in Hydraulic Tank, Add Oil....326
Clean Element in Air Conditioner Fresh Air Filter....327
Every 250 Hours Service....328
Check Battery Electrolyte Level....328
Check Parking Brake....329
Check Alternator Belt Tension, Adjust....330
Check Air Conditioner Compressor Belt Tension, Adjust....332
Check for Loose Wheel Hub Nuts, Tighten....334
Clean Element in Air Conditioner Recirculation Filter....334
Check Function of Brake Accumulator....335
Lubricating....336
Every 500 Hours Service....337
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge....337
Replace Fuel Prefilter Cartridge....339
Every 1000 Hours Service....341
Replace Fuel Main Filter Cartridge....341
Change Oil in Transmission Case, Replace Oil Filter Cartridge, Clean Strainer....343
Clean Transmission Case Breather....344
Lubricating....345
Check Engine Air Intake Piping Clamps for Looseness....345
Replace Corrosion Resistor Cartridge....345
Every 2000 Hours Service....346
Change Oil in Hydraulic Tank, Replace Hydraulic Filter Element....346
Replace Hydraulic Tank Breather Element....349
Change Axle Oil....350
Replace Element in Air Conditioner Recirculation Filter, Fresh Air Filter....351
Check Brake Disc Wear....352
Check Function of PPC Accumulator....354
Check Alternator....355
Check Engine Valve Clearance, Adjust....355
Check Vibration Damper....355
Every 4000 Hours Service....356
Lubricating....356
Check Water Pump....358
Check Starting Motor....358
Check Air Conditioner Compressor, Adjust....358
Check for Loose Engine High-Pressure Piping Clamps, Hardening of Rubber....359
Check for Missing Fuel Spray Prevention Cap, Hardening of Rubber....360
Every 8000 Hours Service....361
Replace High-Pressure Piping Clamps....361
Replace Fuel Spray Prevention Cap....361
SPECIFICATIONS....363
SPECIFICATIONS....364
OPTIONS, ATTACHMENTS....367
JOYSTICK STEERING SYSTEM....368
Structure and Function....368
Components....369
Shift UP, Shift DOWN Switches....370
Directional Selector Switch....370
Joystick Steering Lever....370
Joystick ON/OFF Switch....370
HI/LOW Selector Switch....371
Horn Switch....371
Console Tilt Lever....371
Console Fore-and-Aft Adjustment Lever....371
Joystick Pilot Lamp....372
Armrest Adjustment Lever....372
Steering with Joystick Lever or Steering Wheel....373
Precautions for Steering with Joystick....374
Operating the Joystick Steering System....375
Getting In and Out of Operator’s Cab....378
Adjustments....379
Adjusting Joystick Console....379
Adjusting Seat....380
TORQUE CONVERTER LOCKUP....383
Components....383
Torque Converter Lockup Switch....384
Torque Converter Lockup Pilot Lamp....384
Shift Indicator....384
Character Display....384
Method of Operation....385
Warning/Limit Functions for Travel Speed....386
Travel Speed Warning Function....386
AM/FM RADIO CASSETTE STEREO SOUND SYSTEM....388
Sound System Components....390
Power Switch/Volume....390
Auto-Store/Preset Scan Button....390
Bass Control Knob....390
Treble Control Knob....391
Loudness Button....391
Time/Radio Display Selector Button....391
Tape Eject Button....392
Cassette Door....392
Fast-Forward, Rewind Buttons....392
Preset Buttons....392
Metal Tape Button....393
Manual Tuning Buttons....393
Seek Tuning Buttons....393
Band Selector Button....393
Method of Operation....394
Setting Preset Buttons....394
Using Auto-Preset....394
Using Manual Preset....394
Listening to Radio....395
Listening to Cassette Tape....395
Reversing the Tape....396
Precautions When Using....396
Handling Cassette Tape....396
MULTI-FUNCTION LEVER....397
Components....397
Work Equipment Lever....397
Kickdown Switch....398
Hold Switch....399
FNR Switch....399
Directional Selector Switch Actuation Switch....399
Directional Selector Pilot Lamp....400
Work Equipment Lock Switch....401
Using FNR Switch to Change Between Forward and Reverse....402
CENTRAL LUBRICATION SYSTEM....404
Automatic Greasing Circuit Diagram....404
WHEEL STOPPER....406
BATTERY DISCONNECTOR SWITCH....407
BUCKET AND TIRES....409
CEAM023501 - Wheel Loader WA470-6 Operation & Maintenance Manual....411
INTRODUCTION....413
FOREWORD....414
SAFETY INFORMATION....415
APPROVED AND NON-APPROVED USES....416
Approved Functions....416
Non-Approved Functions....416
VISIBILITY STANDARD....417
Visibility in Immediate Area....417
12-M Radius Visibility....417
PRODUCT IDENTIFICATION....418
Machine....418
Service Meter Location....419
Directions of Machine....419
Machine Serial Number/Product Identification Number (PIN)....420
Engine Serial Number, EPA Regulations....420
SERIAL NUMBERS AND DEALER INFORMATION....421
Model: WA470-6....421
TABLE OF CONTENTS....422
SAFETY....435
SAFETY AND WARNING DECALS....436
Location of the Safety Labels....436
Safety Labels....437
GENERAL SAFETY RULES AND PRECAUTIONS....444
General Safety Rules....444
Safety at Job Site....445
Safety Features....445
Clothing and Protective Equipment....445
Keep Machine Clean....446
Fire and Explosion Prevention....446
Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid....446
Fire Caused by Accumulation of Flammable Material....447
Fire Caused by Electrical Wiring....447
Fire Caused by Piping....447
Explosion Caused by Lighting Equipment....447
Action if Fire Occurs....448
Fire Extinguisher and First Aid Kit....448
Mounting and Dismounting....449
Inside Operator’s Compartment....450
Emergency Escape from Operator’s Cab....450
Precautions When Standing Up from Operator’s Seat....451
Leaving Operator’s Compartment....452
Parking the Machine....453
Transporting the Machine....454
Precautions When Using ROPS....456
Unauthorized Modification....456
Precautions for Attachments and Options....456
Precautions When Cleaning Cab Glass....457
Asbestos Hazard Alert....457
Crush or Pinch-Point Dangers....458
Precautions for Ventilation Exhaust Gas....458
PRECAUTIONS BEFORE STARTING OPERATIONS....459
Pre-Operational Checks....459
Ensure Good Visibility....459
Signs and Signals....459
Precaution for Warning Tag....460
Checks Before Starting Engine, Adjustments....460
Precautions When Starting....461
Precautions in Cold Areas....461
Precautions for Job Site....462
Work Site Hazards....462
Working on Loose or Unstable Ground....462
Prohibited Operations....463
Avoiding Dangerous Situations....463
Working Near High Voltage Cables....465
RULES FOR ROAD TRAVEL....466
Travel Precautions....466
Traveling on Slopes....467
Using the Brakes....468
Traveling in Reverse....468
Operating on Snow or Frozen Surfaces....469
PRECAUTIONS DURING INSPECTION AND MAINTENANCE....470
Warning Tags....470
Workplace Environment....470
Systems Equipped with ECSS....470
Equipment Storage....471
Working at High Places....471
Working Under the Machine....471
Using Drop Lamps....472
Using Proper Tools....472
Keeping the Machine Clean....472
Precautions When Welding....472
Precautions When Using Hammer....473
Noise....473
Stopping Engine During Inspection and Maintenance....474
Running the Machine During Maintenance....476
Rules for Refueling the Machine....477
Cooling System Precautions....477
Window Washer Fluid....477
Battery Information....477
Precautions....477
Hazards....478
Using Booster Cables....479
Starting the Machine with Booster Cables....479
High-Pressure Precautions....480
Precautions for High-Pressure Oil....480
Safe Handling of High-Pressure Hoses....480
Precautions for High-Pressure Fuel....480
High-Temperature Precautions....481
High-Temperature Areas....481
High-Temperature Coolant....481
High-Temperature Oil....481
High Voltage....481
Accumulator and Gas Spring....482
Using Compressed Air....482
Disposal of Waste Materials....482
Inflating Tires....483
Storing Tires....483
Maintenance of Air Conditioner....484
Critical Parts....484
Proper Tools....484
OPERATION....485
GENERAL VIEW....486
General View of Machine....486
General View of Controls and Gauges....487
Machine Monitor....488
Switch Panel....489
EXPLANATION OF COMPONENTS....490
Machine Monitor....490
Types of Warnings....491
Emergency Stop....491
Mistaken Operation....491
Inspection and Maintenance....491
Central Warning Lamp....491
Character Display Portion....492
Service Meter....493
Action Code Display....493
Failure Code Display....494
Filter, Oil Replacement Time Display....495
Emergency Stop Items....497
Brake Oil Pressure Caution Lamp....498
Engine Oil Pressure Caution Lamp....498
Battery Charge Circuit Caution Lamp....499
Steering Oil Pressure Caution Lamp (if equipped)....499
Caution Items....500
Brake Oil Temperature Caution Lamp....501
Torque Converter Oil Temperature Caution Lamp....501
Engine Coolant Temperature Caution Lamp....502
Hydraulic Oil Temperature Caution Lamp....502
Fuel Level Caution Lamp....502
Inspection and Maintenance Items....503
Radiator Coolant Level Caution Lamp....503
Engine Oil Level Caution Lamp....504
Battery Electrolyte Level Caution Lamp (if equipped)....504
Maintenance Caution Lamp....504
Air Cleaner Clogging Caution Lamp....505
Water Separator Caution Lamp....505
Transmission Oil Filter Clogging Caution Lamp....505
Pilot Display Portion....506
Parking Brake Pilot Lamp....507
Cooling Fan Reverse Rotation Pilot Lamp....507
Emergency Steering Pilot Lamp (if equipped)....507
Power Mode Pilot Lamp (P Mode)....508
Preheating Pilot Lamp....508
Semi-Auto Digging Pilot Lamp....508
Auto-Greasing Pilot Lamp (if equipped)....508
Joystick Pilot Lamp (if equipped)....508
Directional Selector Pilot Lamp (if equipped)....508
Economy Operation Display Lamp....509
Shift Indicator....509
Auto-Shift Pilot Lamp....509
Torque Converter Lockup Pilot Light (if equipped)....509
Shift Hold Pilot Lamp....510
Shift Lever Position Pilot Lamp....510
Turn Signal Pilot Lamp....510
Head Lamp High-Beam Pilot Lamp....510
Meter Display Portion....511
Torque Converter Oil Temperature Gauge....511
Engine Coolant Temperature Gauge....512
Hydraulic Oil Temperature Gauge....512
Fuel Gauge....512
Speedometer....513
Meter Display Pilot Lamp....513
OTHER FUNCTIONS OF MACHINE MONITOR....514
Overall Menu....514
Displaying Odometer....516
Resetting Filter, Oil Replacement Time....516
Entering Telephone Number....517
Selecting Language....518
Adjusting Monitor Brightness....520
Switching Travel Speed/Engine Speed Display....522
Switching Travel Speed/Engine Speed Display/Non-Display....523
SWITCHES AND CONTROLS....524
General View....524
Starting Switch....526
Power Mode Selector Switch....526
Transmission Shift Mode Selector Switch....527
Transmission Cutoff Switch....527
Transmission Cutoff Set Switch....528
Lamp Switch....528
Turn Signal Lever....528
Dimmer Switch....529
Horn Button....529
Hazard Lamp Switch....529
Parking Brake Switch....530
Front Working Lamp Switch....530
Rear Working Lamp Switch....531
Machine Monitor Mode Selector Switch 1....531
Machine Monitor Mode Selector Switch 2....531
Kickdown Switch....532
Hold Switch....533
Front Wiper Switch....533
Rear Wiper Switch....534
Cigarette Lighter....534
Room Lamp Switch....534
Rear Heated Wire Glass Switch....534
ECSS Switch....535
Emergency Steering Switch (if equipped)....535
Cooling Fan Auto-Reverse Rotation Switch....536
Torque Converter Lockup Switch....539
CONTROL LEVERS, PEDALS....540
General View....540
Gearshift Lever....541
Directional Lever....542
Gearshift Lever Stopper....543
Work Equipment Lock Lever....543
Bucket Control Lever....544
Lift Arm Control Lever....544
Brake Pedals....545
Accelerator Pedal....545
SECURITY LOCKS AND SAFETY FEATURES....546
Steering Tilt Lock Lever....546
Frame Lock Bar....547
Cap with Lock....548
Fuel Tank Filler Port Cap....548
Hydraulic Tank Filler Port Cap....548
Backup Alarm....549
MACHINE FEATURES....550
Towing Pin....550
Grease Pump....550
Cab Door....551
Emergency Escape Right Door....551
Left Cab Door, Door Open Lock....553
Left Cab Door, Knob....554
Left Cab Door, Handle....554
Left Cab Sliding Window (Lock Release Knob)....554
Cab Wiper....555
Dust Indicator....555
Fire Extinguisher (if equipped)....555
ELECTRICAL....556
Power Outlet....556
Fuses....556
Fuse Capacity and Name of Circuit....557
Slow-Blow Fuse....558
WORK OPERATIONS....559
Walk-Around Check....559
Precautions Before Starting Work Operations....559
Check Before Starting Engine....564
Check Machine Monitor....564
Check Coolant Level, Add Coolant....565
Check Oil Level in Engine Oil Pan, Add Oil....566
Check Water Separator, Drain Water....567
Check Air Cleaner....568
Check Fuel Level, Add Fuel....569
Check Electric Wiring....570
Adjustments....572
Adjusting Seat....572
Removing or Installing Headrest....574
Seat Belt Inspection....575
Adjusting Seat Belt....576
Adjusting Lever Stand....577
Adjusting Mirrors....578
Final Checks Before Starting Engine....579
Starting Engine....581
Normal Starting....581
Starting in Cold Weather....583
Automatic Warming-Up Operation....584
Operations and Checks After Starting Engine....585
Checks After Starting Engine....585
Breaking in the Machine....586
Normal Operation....586
Stopping Engine....588
Check After Stopping Engine....588
Moving the Machine (Directional, Speed), Stopping the Machine....590
Moving the Machine....590
Changing Gear Speed....593
Changing Direction....594
Stopping the Machine....596
Transmission Cutoff Function....597
Turning....599
Emergency Steering (if equipped)....600
Emergency Steering Self-Check Function....601
Operation of Work Equipment....602
Work Equipment Lock Lever....602
Lift Arm Control Lever....602
Bucket Control Lever....603
Work Possible Using Wheel Loader....605
Digging Operations....605
Loading Piled Soil or Blasted Rock....605
Digging and Loading on Level Ground....607
Leveling Operations....608
Pushing Operations....608
Load-and-Carry Operations....609
Loading Operations....610
Cross-Drive Loading....610
V-Shape Loading....610
Preparations for Loading, Gathering Rocks....611
Approaching Facing....611
Digging....612
Traveling in Reverse After Excavation....614
Approaching Dump Truck....615
Loading Dump Truck....616
Reversing Away From Dump Truck....617
Precautions During Work Operations....618
Piling Up Loads....618
Handling Blasted Rock....618
Loosened Boulders....622
Pit Excavation....622
Cutting Face Operations....622
Switching Between Forward and Reverse....622
Turning When Tires are Stationary....623
Wheel Brake Does Not Work....623
Braking Function....623
Lower the Center of Gravity when Turning....624
Permissible Water Depth....624
Driving Up or Down Slopes....624
Driving the Machine....625
Adjusting Work Equipment....626
Adjusting Boom Kickout....626
Adjusting Bucket Positioner....627
Bucket Level Indicator....628
Measuring Dump Angle....629
Measuring Bucket Dump Angle....629
Measuring Coupler Dump Angle....632
Parking the Machine....635
Checks After Completion of Operation....637
Before Stopping Engine....637
After Stopping Engine....637
Locking the Machine....638
HANDLING TIRES....640
Precautions When Handling Tires....640
Tire Pressure....641
Precautions for Using Load-and-Carry Method....642
TRANSPORTATION....643
Transportation Procedure....643
Loading and Unloading Trailers....644
Loading Machine....644
Securing Machine....645
Unloading Machine....647
LIFTING MACHINE....648
Lifting Position....648
Lifting Procedure....649
COLD WEATHER OPERATION....650
Precautions for Low Temperature....650
Fuel and Lubricants....650
Coolant....650
Battery....651
Precautions After Completion of Work....651
After Cold Weather....651
LONG-TERM STORAGE....652
Before Storage....652
During Storage....652
After Storage....652
AUTOMATIC AIR CONDITIONER....653
Control Panel....653
Main Power Switch....654
Fan Switch....654
Air Conditioner Switch....655
Auto Switch....656
Temperature Switch....656
FRESH/RECIRC Selector Switch....656
Mode Selector Switch....657
Method of Operation....658
Cooling Operation....658
Heating Operation....658
Drying-Heating and Demisting Operation....659
When Not Using the Air Conditioner Regularly....659
Precautions When Using Air Conditioner....659
Inspection and Maintenance....660
Cool Box....660
KOMTRAX....661
Basic Precautions....661
TROUBLESHOOTING....662
When Machine Runs Out of Fuel....662
Towing the Machine....662
When Engine Can Be Used....663
When Engine Cannot Be Used....663
Releasing Parking Brake....664
Emergency Travel Operation....666
If Battery is Discharged....667
Precautions....667
Removal and Installation of Battery....667
Precautions for Charging Battery....668
Starting Engine With Booster Cables....669
Precautions When Connecting or Disconnecting Booster Cable....669
Connecting Booster Cable....669
Starting Engine....670
Disconnecting Booster Cable....670
Lowering Work Equipment When Engine Has Stopped....671
Other Troubleshooting....672
Electrical System....672
Chassis....673
Engine....675
MAINTENANCE....677
GUIDES TO MAINTENANCE....678
Check Service Meter....678
Komatsu Genuine Replacement Parts....678
Komatsu Genuine Oils....678
Always Use Clean Washer Fluid....678
Always Use Clean Oil and Grease....678
Checking for Foreign Materials in Drained Oil and On Filters....678
Fuel Strainer....678
Welding Instructions....679
Do Not Drop Things Inside Machine....679
Dusty Work Sites....679
Avoid Mixing Oil....679
Locking Inspection Covers....679
Bleeding Air from Hydraulic Circuit....679
Precautions When Installing Hydraulic Hoses....680
Checks After Inspection and Maintenance....680
OUTLINES OF SERVICE....681
Handling Oil, Fuel, Coolant, and Performing Oil Clinic....681
Oil....681
Fuel....682
Coolant and Water for Dilution....682
Grease....683
Storing Oil and Fuel....683
Filters....683
Performing KOWA (Komatsu Oil Wear Analysis)....684
KOWA Analysis Items....684
Oil Sampling....684
Outline of Electric System....685
WEAR PARTS....686
Wear Parts List....686
RECOMMENDED FUEL, COOLANT, AND LUBRICANTS....687
Fuel, Coolant, and Lubricant Ambient Temperature Chart....688
Recommended Brands, Other Than Komatsu Genuine Oil....689
Biodiesel Usage....690
Biodiesel Recommendation for Komatsu Engines....690
Biodiesel Terminology....690
Certification and Standards....691
Warranty and Use of Biodiesel Fuel in Komatsu Engines....691
Requirements for Using Biodiesel Fuel in Komatsu Engines....691
Properties of Biodiesel....692
Komatsu Biodiesel Blend Specification for B5 to B20....693
Summary of Recommendations....694
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....695
Torque List....695
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....697
Safety Critical Parts List....698
MAINTENANCE SCHEDULE CHART....700
SERVICE PROCEDURE....702
Initial 250 Hours Service....702
Initial 1000 Hours Service....702
When Required....703
Clean, Replace Air Cleaner Element....703
Clean Inside of Cooling System....707
Check Transmission Oil, Add Oil....711
Check Axle Oil Level, Add Oil....713
Clean Axle Case Breather....715
Clean Air Conditioner Condenser....716
Check Window Washing Fluid Level, Add Fluid....716
Clean Radiator Fins and Cooler Fins....717
Turn, Replace Bolt-On Cutting Edge....720
Replace Bucket Teeth (if equipped)....721
Check Air Conditioner....724
Replace Slow-Blow Fuse....726
Check Function of Accumulator....727
Select Tires....728
Check Tire Pressure....729
Clean, Replace Fuel Breather Filter....730
Check Before Starting....732
Every 50 Hours Service....733
Drain Water, Sediment from Fuel Tank....733
Every 100 Hours Service....734
Lubricate Rear Axle Pivot Pin....734
Check Oil Level in Hydraulic Tank, Add Oil....734
Clean Element in Air Conditioner Fresh Air Filter....735
Every 250 Hours Service....736
Check Battery Electrolyte Level....736
Check Parking Brake....737
Check Alternator Belt Tension, Adjust....738
Check Air Conditioner Compressor Belt Tension, Adjust....740
Check for Loose Wheel Hub Nuts, Tighten....742
Clean Element in Air Conditioner Recirculation Filter....742
Check Function of Brake Accumulator....743
Lubricating....744
Every 500 Hours Service....745
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge....745
Replace Fuel Prefilter Cartridge....747
Every 1000 Hours Service....749
Replace Fuel Main Filter Cartridge....749
Change Oil in Transmission Case, Replace Oil Filter Cartridge, Clean Strainer....751
Clean Transmission Case Breather....752
Lubricating....753
Check Engine Air Intake Piping Clamps for Looseness....753
Every 2000 Hours Service....754
Change Oil in Hydraulic Tank, Replace Hydraulic Filter Element....754
Replace Hydraulic Tank Breather Element....757
Change Axle Oil....758
Replace Element in Air Conditioner Recirculation Filter, Fresh Air Filter....759
Check Brake Disc Wear....760
Check Function of PPC Accumulator....762
Check Alternator....763
Check Engine Valve Clearance, Adjust....763
Check Vibration Damper....763
Every 4000 Hours Service....764
Lubricating....764
Check Water Pump....766
Check Starting Motor....766
Check Air Conditioner Compressor, Adjust....766
Check for Loose Engine High-Pressure Piping Clamps, Hardening of Rubber....767
Check for Missing Fuel Spray Prevention Cap, Hardening of Rubber....768
Every 8000 Hours Service....769
Replace High-Pressure Piping Clamps....769
Replace Fuel Spray Prevention Cap....769
SPECIFICATIONS....771
SPECIFICATIONS....772
OPTIONS, ATTACHMENTS....775
JOYSTICK STEERING SYSTEM....776
Structure and Function....776
Components....777
Shift UP, Shift DOWN Switches....778
Directional Selector Switch....778
Joystick Steering Lever....778
Joystick ON/OFF Switch....778
HI/LOW Selector Switch....779
Horn Switch....779
Console Tilt Lever....779
Console Fore-and-Aft Adjustment Lever....779
Joystick Pilot Lamp....780
Armrest Adjustment Lever....780
Steering with Joystick Lever or Steering Wheel....781
Precautions for Steering with Joystick....782
Operating the Joystick Steering System....783
Getting In and Out of Operator’s Cab....786
Adjustments....787
Adjusting Joystick Console....787
Adjusting Seat....788
TORQUE CONVERTER LOCKUP....791
Components....791
Torque Converter Lockup Switch....792
Torque Converter Lockup Pilot Lamp....792
Shift Indicator....792
Character Display....792
Method of Operation....793
Warning/Limit Functions for Travel Speed....794
Travel Speed Warning Function....794
AM/FM RADIO CASSETTE STEREO SOUND SYSTEM....796
Sound System Components....798
Power Switch/Volume....798
Auto-Store/Preset Scan Button....798
Bass Control Knob....798
Treble Control Knob....799
Loudness Button....799
Time/Radio Display Selector Button....799
Tape Eject Button....800
Cassette Door....800
Fast-Forward, Rewind Buttons....800
Preset Buttons....800
Metal Tape Button....801
Manual Tuning Buttons....801
Seek Tuning Buttons....801
Band Selector Button....801
Method of Operation....802
Setting Preset Buttons....802
Using Auto-Preset....802
Using Manual Preset....802
Listening to Radio....803
Listening to Cassette Tape....803
Reversing the Tape....804
Precautions When Using....804
Handling Cassette Tape....804
AM/FM RADIO CD STEREO SOUND SYSTEM....805
MULTI-FUNCTION LEVER....806
Components....806
Work Equipment Lever....806
Kickdown Switch....807
Hold Switch....808
FNR Switch....808
Directional Selector Switch Actuation Switch....808
Directional Selector Pilot Lamp....809
Work Equipment Lock Switch....810
Using FNR Switch to Change Between Forward and Reverse....811
WHEEL STOPPER....813
BATTERY DISCONNECTOR SWITCH....814
BUCKET AND TIRES....816
CEAM026700 - Wheel Loader WA470-7 Operation & Maintenance Manual....817
COVER....817
FOREWORD ....819
BEFORE READING THIS MANUAL ....820
SAFETY INFORMATION ....821
INTRODUCTION ....822
USE OF MACHINE ....822
DIRECTIONS OF MACHINE ....822
PRODUCT INFORMATION ....823
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ....823
EPA REGULATIONS, ENGINE NUMBER PLATE ....823
SERVICE METER LOCATION ....824
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ....824
CONTENTS ....825
SAFETY ....829
SAFETY ....830
SAFETY LABELS ....832
LOCATION OF SAFETY LABELS ....832
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ....841
PRECAUTIONS BEFORE STARTING OPERATION ....841
PREPARATIONS FOR SAFE OPERATION ....842
FIRE PREVENTION ....844
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE ....846
DO NOT GET CAUGHT IN WORK EQUIPMENT ....849
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ....849
UNAUTHORIZED MODIFICATION ....849
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ....850
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ....850
PRECAUTIONS FOR OPERATION ....851
PRECAUTIONS FOR JOBSITE ....851
STARTING ENGINE ....854
OPERATION ....857
TRANSPORTATION ....863
TOWING ....864
PRECAUTIONS FOR MAINTENANCE ....865
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ....865
PRECAUTIONS FOR INSPECTION AND MAINTENANCE ....870
TIRES ....874
OPERATION ....875
GENERAL VIEW ....876
GENERAL VIEW OF MACHINE ....876
GENERAL VIEW OF CONTROLS AND GAUGES ....878
SWITCH PANEL ....879
MACHINE MONITOR ....880
EXPLANATION OF COMPONENTS ....882
MACHINE MONITOR ....882
SWITCHES ....954
CONTROL LEVERS AND PEDALS ....968
OIL FILLER CAP ....974
ASHTRAY ....976
FRAME LOCK BAR ....977
TOWING PIN ....978
GREASE PUMP HOLDER ....979
BATTERY DISCONNECT SWITCH ....980
SYSTEM OPERATING LAMP ....982
BACKUP ALARM ....983
OPEN AND CLOSE CAB DOOR ....984
FUSE ....988
SLOW BLOW FUSE ....990
AUXILIARY ELECTRIC POWER ....991
OPTIONAL POWER SUPPLY OUTLET ....992
HANDLING RADIO ....993
HANDLING AUTO AIR CONDITIONER ....998
HANDLING FRONT WIPER ....1009
FIRE EXTINGUISHER ....1010
HANDLING REAR VIEW MONITOR ....1011
HANDLING Komatsu Diesel Particulate Filter (KDPF) ....1012
HANDLING Komatsu Closed Crankcase Ventilation (KCCV) ....1020
HANDLING MACHINES EQUIPPED WITH KOMTRAX ....1021
MACHINE OPERATIONS AND CONTROLS ....1023
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ....1023
STARTING ENGINE ....1046
CHECKS AFTER STARTING ENGINE ....1051
STOPPING ENGINE ....1054
MACHINE OPERATION ....1055
STEERING MACHINE ....1065
WORK EQUIPMENT CONTROLS AND OPERATIONS ....1069
RECOMMENDED APPLICATIONS ....1071
RULES FOR OPERATION ....1077
BUCKET LEVEL INDICATOR ....1079
REMOTE POSITIONER ....1080
PARKING MACHINE ....1084
CHECK AFTER FINISHING WORK ....1086
LOCKING ....1087
HANDLING TIRES ....1088
TRANSPORTATION ....1090
TRANSPORTATION PROCEDURE ....1090
LOADING AND UNLOADING WITH TRAILER ....1091
LIFTING MACHINE ....1095
COLD WEATHER OPERATION ....1097
COLD WEATHER OPERATION INFORMATION ....1097
AFTER DAILY WORK COMPLETION ....1098
IN COLD AREAS ....1098
AFTER COLD WEATHER SEASON ....1098
LONG-TERM STORAGE ....1099
BEFORE STORAGE ....1099
DURING STORAGE ....1099
AFTER STORAGE ....1100
STARTING MACHINE AFTER LONG-TERM STORAGE ....1100
TROUBLES AND ACTIONS ....1101
RUNNING OUT OF FUEL ....1101
TOWING MACHINE ....1102
DISCHARGED BATTERY ....1107
OTHER TROUBLE ....1111
MAINTENANCE ....1117
RULES FOR MAINTENANCE ....1118
SERVICE METER READING ....1118
KOMATSU GENUINE REPLACEMENT PARTS ....1118
KOMATSU GENUINE LUBRICANTS ....1118
ALWAYS USE CLEAN WASHER FLUID ....1118
FRESH AND CLEAN LUBRICANTS ....1118
CHECK DRAINED OIL AND USED FILTER ....1118
CAUTION FOR REFILLING OIL OR FUEL ....1118
WELDING INSTRUCTIONS ....1118
DO NOT DROP THINGS INSIDE MACHINE ....1118
PRECAUTIONS FOR KDPF ....1118
DUSTY JOBSITES ....1118
AVOID MIXING OIL ....1119
LOCKING INSPECTION COVERS ....1119
BLEEDING AIR FROM HYDRAULIC CIRCUIT ....1119
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ....1119
CHECKS AFTER INSPECTION AND MAINTENANCE ....1119
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE ....1119
CLOSE ENGINE SIDE COVER SECURELY ....1119
OUTLINE OF MAINTENANCE ....1120
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ....1120
HANDLING ELECTRICAL COMPONENTS ....1124
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS ....1125
TIGHTENING TORQUE LIST ....1125
MAINTENANCE SCHEDULE ....1126
MAINTENANCE SCHEDULE TABLE ....1126
MAINTENANCE PROCEDURE ....1128
INITIAL 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 50 HOURS) ....1128
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ....1128
WHEN REQUIRED ....1129
CHECKS BEFORE STARTING ....1152
EVERY 50 HOURS MAINTENANCE ....1153
EVERY 100 HOURS MAINTENANCE ....1154
EVERY 250 HOURS MAINTENANCE ....1156
EVERY 500 HOURS MAINTENANCE ....1165
EVERY 1000 HOURS MAINTENANCE ....1168
EVERY 2000 HOURS MAINTENANCE ....1173
EVERY 4000 HOURS MAINTENANCE ....1183
EVERY 4500 HOURS MAINTENANCE ....1186
EVERY 8000 HOURS MAINTENANCE ....1188
EVERY 9000 HOURS MAINTENANCE ....1189
SPECIFICATIONS ....1191
SPECIFICATIONS ....1192
ATTACHMENTS AND OPTIONS ....1195
TIRE AND BUCKET SELECTION ....1196
REPLACEMENT PARTS ....1197
SAFETY CRITICAL PARTS ....1198
SAFETY CRITICAL PARTS LIST ....1198
CONSUMABLE PARTS ....1199
CONSUMABLE PARTS LIST ....1199
RECOMMENDED FUEL, COOLANT, AND LUBRICANT ....1200
LUBRICATION CHART ....1200
LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE AND RECOMMENDED GENUINE LUBRICANTS ....1203
RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL ....1205
INDEX ....1207
CEBM027200 - Wheel Loader WA470-7 Shop Manual....1210
CEBM027200 - WA470-7 s/n A47001 - and up....1210
00 Index and foreword ....1212
Index ....1213
Foreword, safety and general information ....1229
Important safety notice ....1229
How to read the shop manual ....1236
Explanation of terms for maintenance standard ....1238
Handling equipment of fuel system devices ....1240
Handling of intake system parts ....1241
Handling of hydraulic equipment ....1242
Method of disconnecting and connecting of push-pull type coupler ....1244
Handling of electrical equipment ....1247
How to read electric wire code ....1255
Precautions when performing operation ....1258
Practical use of KOMTRAX ....1262
Standard tightening torque table ....1263
List of abbreviation ....1267
Conversion table ....1272
01 Specification ....1278
Table of contents ....1279
Specifications ....1280
Specification drawing ....1280
Specifications ....1282
Weight table ....1288
Table of fuel, coolant, and lubricants ....1290
10 Structure and function ....1292
Table of contents ....1293
Engine and cooling system ....1295
Engine related parts ....1295
KVGT ....1297
EGR system piping drawing ....1303
EGR system circuit diagram ....1305
EGR valve ....1306
EGR cooler ....1308
KCCV layout drawing ....1310
KCCV ventilator ....1312
KDPF ....1314
Cooling system ....1318
Cooling fan pump ....1321
Cooling fan motor ....1330
Power train ....1337
Power train system ....1337
Drive shaft ....1340
Power train piping drawing ....1341
Transmission control ....1342
Torque converter ....1345
Transmission ....1350
Transmission control valve ....1369
Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV ....1372
3rd, 4th clutch ECMV ....1379
Lockup clutch ECMV ....1386
Main relief and torque converter relief valve ....1390
Axle ....1392
Differential ....1394
Final drive ....1404
Steering system ....1406
Layout of steering parts ....1406
Steering column ....1407
Steering pump ....1408
Steering valve ....1420
Orbit-roll valve ....1434
Stop valve ....1440
Emergency steering motor ....1441
Emergency steering pump ....1442
Brake system ....1443
Layout of brake parts ....1443
Charge valve ....1445
Brake valve ....1451
Slack adjuster ....1455
Accumulator (for brake) ....1458
Brake ....1459
Parking brake control ....1462
Parking brake ....1463
Parking brake solenoid valve ....1464
Parking brake emergency release valve ....1467
Undercarriage and frame ....1468
Axle mount and center hinge pin ....1468
Tire ....1469
Hydraulic system ....1471
Hydraulic component layout ....1471
Work equipment control ....1473
Hydraulic tank ....1474
Double type gear pump ....1477
Work equipment pump ....1478
Control valve ....1499
CLSS ....1508
Hydraulic circuit diagram and names of valves ....1512
Accumulator charge valve ....1523
Work equipment lock solenoid valve ....1527
Accumulator (for PPC circuit) ....1528
Accumulator (for ECSS) ....1529
Work equipment ....1530
Work equipment linkage ....1530
Bucket ....1531
Bucket positioner and boom positioner ....1532
Cab and its attachments ....1533
ROPS cab ....1533
Electrical system ....1534
Engine control system ....1534
Preheating system ....1536
Engine power mode selector circuit ....1538
Engine output limit function ....1539
Automatic warm-up function ....1540
Parking brake control system ....1541
System operating lamp function ....1543
Battery disconnect switch function ....1545
Transmission controller system ....1547
Work equipment control system ....1568
Machine monitor system ....1584
Rear view monitor system ....1608
KOMTRAX system ....1611
System component parts ....1614
Sensor ....1641
20 Standard value tables ....1670
Table of contents ....1671
Standard service value table ....1672
Standard value table for engine ....1672
Standard value table for machine ....1674
Standard value table for electrical system ....1687
30 Testing and adjusting ....1702
Table of contents ....1703
General information on testing and adjusting ....1705
Tools for testing and adjusting ....1705
Sketch of tools for testing and adjusting ....1709
Engine and cooling system ....1711
Testing engine speed ....1711
Testing boost pressure ....1713
Testing exhaust gas color ....1715
Testing and adjusting valve clearance ....1717
Testing compression pressure ....1719
Testing blowby pressure ....1723
Testing engine oil pressure ....1725
Testing EGR valve and KVGT oil pressures ....1726
Testing fuel pressure ....1727
Testing fuel return rate and leakage ....1728
Bleeding air from fuel system ....1732
Testing fuel circuit for leakage ....1734
Handling cylinder cutout mode operation ....1735
Handling no injection cranking operation ....1736
Testing of KDPF and muffler stack for looseness and damage ....1737
Testing of installed condition of cylinder head and manifolds ....1738
Testing engine piping for damage and looseness ....1739
Testing and adjusting air conditioner compressor belt tension ....1740
Testing and adjusting alternator belt tension ....1742
Procedures for cleaning fuel doser ....1744
Writing compensation values at replacement of injector and engine controller ....1747
Power train ....1751
Adjusting transmission output speed sensor ....1751
Adjusting transmission input speed sensor ....1752
Flushing procedure for torque converter and transmission hydraulic circuit ....1753
Retrieval of disabled machine due to transmission valve failure ....1755
Testing oil leakage from axle final drive ....1757
Testing drive shaft for looseness, backlash, and damage ....1758
Testing and adjusting power train oil pressure ....1759
Steering system ....1774
Testing directional lever ....1774
Testing steering wheel ....1775
Testing work equipment control lever ....1777
Testing and adjusting steering circuit oil pressure ....1779
Bleeding air from steering cylinder circuit. ....1782
Testing and adjusting steering stopper valve ....1783
Brake system ....1784
Testing brake pedal ....1784
Testing and adjusting brake pedal linkage ....1785
Testing braking performance ....1786
Testing and adjusting of accumulator charge pressure ....1787
Testing of brake accumulator nitrogen gas pressure and procedure for charging brake accumulator with nitrogen gas ....1789
Testing wheel brake oil pressure ....1793
Testing lowering of wheel brake pressure ....1795
Testing wear of wheel brake disc ....1797
Bleeding air from wheel brake circuit ....1798
Releasing remaining pressure in brake accumulator circuit ....1800
Testing parking brake performance ....1801
Testing parking brake oil pressure ....1802
Testing wear of parking brake disc ....1803
Method of releasing parking brake manually ....1804
Hydraulic system ....1806
Testing fan speed ....1806
Testing fan pump circuit oil pressure ....1807
Bleeding air from hydraulic fan circuit ....1809
Testing and adjusting work equipment EPC oil pressure ....1811
Testing and adjusting work equipment oil pressure ....1814
Bleeding air from work equipment circuit ....1818
Releasing remaining pressure from work equipment circuit ....1819
Testing of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ....1820
Work equipment ....1824
Testing and adjusting bucket position detection lever ....1824
Testing and adjusting boom position detection lever ....1825
Electrical system ....1826
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ....1826
Special functions of machine monitor ....1828
Adjusting rearview camera angle ....1917
Handling voltage circuit of engine controller ....1918
Handling battery disconnect switch ....1919
Testing diodes ....1920
Pm clinic ....1921
Pm Clinic service ....1921
Check sheet ....1922
40 Troubleshooting ....1928
Table of contents ....1929
General information on troubleshooting ....1938
Troubleshooting points ....1938
Sequence of events in troubleshooting ....1940
Check before troubleshooting ....1942
Inspection procedure before troubleshooting ....1944
Preparation work for troubleshooting of electrical system ....1961
Classification and procedures for troubleshooting ....1967
Symptom and troubleshooting numbers ....1970
Information in troubleshooting table ....1973
Connector list and layout ....1975
Connector contact identification ....1989
T-branch box and T-branch adapter table ....2025
Fuse location table ....2031
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ....2034
Precautions on troubleshooting of machine monitor ....2037
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ....2039
Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors) ....2044
Fabrication of short-circuit connector (for CA1883 and CA3135) ....2045
Failure codes table ....2046
Troubleshooting by failure code (Display of code) ....2060
Failure code [1500L0] Double Engagement of T/M Clutches ....2060
Failure code [15SAL1] Release Trouble of ECMV (Forward) ....2061
Failure code [15SALH] Malfunction of ECMV (Forward) ....2063
Failure code [15SBL1] Release Trouble of ECMV (Reverse) ....2065
Failure code [15SBLH] Malfunction of ECMV (Reverse) ....2067
Failure code [15SEL1] Release Trouble of ECMV (1st) ....2069
Failure code [15SELH] Malfunction of ECMV (1st) ....2071
Failure code [15SFL1] Release Trouble of ECMV (2nd) ....2073
Failure code [15SFLH] Malfunction of ECMV (2nd) ....2075
Failure code [15SGL1] Release Trouble of ECMV (3rd) ....2077
Failure code [15SGLH] Malfunction of ECMV (3rd) ....2079
Failure code [15SHL1] Release Trouble of ECMV (4th) ....2081
Failure code [15SHLH] Malfunction of ECMV (4th) ....2083
Failure code [2F00MA] Failure of Parking Brake Circuit ....2085
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ....2089
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ....2091
Failure code [879AKA] A/C Inner Sensor Open Circuit ....2093
Failure code [879AKB] A/C Inner Sensor Short Circuit ....2094
Failure code [879BKA] A/C Outer Sensor Open Circuit ....2095
Failure code [879BKB] A/C Outer Sensor Short Circuit ....2096
Failure code [879CKA] Ventilating Sensor Open Circuit ....2097
Failure code [879CKB] Ventilating Sensor Short Circuit ....2098
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ....2099
Failure code [879EMC] Ventilation Damper Abnormality ....2100
Failure code [879FMC] Air Mix Damper Abnormality ....2101
Failure code [989A00] Engine Overrun Prevention Activated ....2102
Failure code [989L00] Engine Controller Lock Caution 1 ....2103
Failure code [989M00] Engine Controller Lock Caution 2 ....2104
Failure code [989N00] Engine Controller Lock Caution 3 ....2105
Failure code [A1U0N3] HC Desorb Request 1 ....2106
Failure code [A1U0N4] HC Desorb Request 2 ....2108
Failure code [AA10NX] Air Cleaner Clogging ....2110
Failure code [B@BAZG] Eng Oil Press Low ....2112
Failure code [B@BAZK] Eng Oil Level Low ....2113
Failure code [B@BCNS] Eng Water Overheat ....2115
Failure code [B@BCZK] Eng Water Level Low ....2116
Failure code [B@CENS] T/C Oil Temp. Overheat ....2118
Failure code [B@HANS] HYD Oil Temp. Overheat ....2119
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ....2120
Failure code [CA122] Chg Air Press Sensor High Error ....2121
Failure code [CA123] Chg Air Press Sensor Low Error ....2123
Failure code [CA131] Throttle Sensor High Error ....2125
Failure code [CA132] Throttle Sensor Low Error ....2127
Failure code [CA135] Eng Oil Press Sensor High Error ....2129
Failure code [CA141] Eng Oil Press Sensor Low Error ....2131
Failure code [CA144] Coolant Temp Sens High Error ....2133
Failure code [CA145] Coolant Temp Sens Low Error ....2135
Failure code [CA153] Chg Air Temp Sensor High Error ....2137
Failure code [CA154] Chg Air Temp Sensor Low Error ....2139
Failure code [CA187] Sensor 2 Supply Volt Low Error ....2141
Failure code [CA221] Ambient Press Sensor High Error ....2143
Failure code [CA222] Ambient Press Sensor Low Error ....2145
Failure code [CA227] Sensor 2 Supply Volt High Error ....2147
Failure code [CA234] Eng Overspeed ....2148
Failure code [CA238] Ne Speed Sensor Supply Volt Error ....2149
Failure code [CA239] Ne Speed Sens Supply Volt High Error ....2150
Failure code [CA271] IMV/PCV1 Short Error ....2151
Failure code [CA272] IMV/PCV1 Open Error ....2152
Failure code [CA273] PCV2 Short Error ....2153
Failure code [CA274] PCV2 Open Error ....2154
Failure code [CA322] Inj #1(L#1) Open/Short Error ....2155
Failure code [CA323] Inj #5(L#5) Open/Short Error ....2157
Failure code [CA324] Inj #3(L#3) Open/Short Error ....2159
Failure code [CA325] Inj #6(L#6) Open/Short Error ....2161
Failure code [CA331] Inj #2(L#2) Open/Short Error ....2163
Failure code [CA332] Inj #4(L#4) Open/Short Error ....2165
Failure code [CA343] ECM Critical Internal Failure ....2167
Failure code [CA351] Injectors Drive Circuit Error ....2168
Failure code [CA352] Sensor 1 Supply Volt Low Error ....2169
Failure code [CA356] Mass Air Flow Sensor High Error ....2171
Failure code [CA357] Mass Air Flow Sensor Low Error ....2173
Failure code [CA386] Sensor 1 Supply Volt High Error ....2175
Failure code [CA431] Idle Validation Sw Error ....2176
Failure code [CA432] Idle Validation Process Error ....2179
Failure code [CA441] Battery Voltage Low Error ....2182
Failure code [CA442] Battery Voltage High Error ....2184
Failure code [CA449] Rail Press Very High Error ....2185
Failure code [CA451] Rail Press Sensor High Error ....2186
Failure code [CA452] Rail Press Sensor Low Error ....2188
Failure code [CA515] Rail Press Sens Sup Volt High Error ....2190
Failure code [CA516] Rail Press Sens Sup Volt Low Error ....2192
Failure code [CA553] Rail Press High Error ....2194
Failure code [CA555] Crankcase Press High Error 1 ....2195
Failure code [CA556] Crankcase Press High Error 2 ....2196
Failure code [CA559] Rail Press Low Error ....2197
Failure code [CA595] Turbo Speed High Error 2 ....2201
Failure code [CA687] Turbo Speed Low Error ....2202
Failure code [CA689] Eng Ne Speed Sensor Error ....2204
Failure code [CA691] Intake Air Temp Sens High Error ....2206
Failure code [CA692] Intake Air Temp Sens Low Error ....2208
Failure code [CA697] ECM Internal Temp Sensor High Error ....2210
Failure code [CA698] ECM Int Temp Sensor Low Error ....2211
Failure code [CA731] Eng Bkup Speed Sens Phase Error ....2212
Failure code [CA778] Eng Bkup Speed Sensor Error ....2213
Failure code [CA1117] Persistent Data Lost Error ....2215
Failure code [CA1664] KDOC Malfunction ....2216
Failure code [CA1691] Regeneration Ineffective ....2219
Failure code [CA1695] Sensor 5 Supply Volt High Error ....2222
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....2223
Failure code [CA1843] Crankcase Press Sens High Error ....2225
Failure code [CA1844] Crankcase Press Sens Low Error ....2227
Failure code [CA1879] KDPF Delta P Sensor High Error ....2229
Failure code [CA1881] KDPF Delta P Sensor Low Error ....2231
Failure code [CA1883] KDPF Delta P Sens In Range Error ....2233
Failure code [CA1921] KDPF Soot Load High Error 1 ....2236
Failure code [CA1922] KDPF Soot Load High Error 2 ....2239
Failure code [CA1923] Dosing Fuel Valve 1 High Error ....2244
Failure code [CA1924] Dosing Fuel Valve 1 Low Error ....2246
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ....2249
Failure code [CA1927] Dosing Fuel Press Sens High Error ....2251
Failure code [CA1928] Dosing Fuel Press Sens Low Error ....2253
Failure code [CA1942] Crankcase Press Sens In Range Error ....2255
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ....2256
Failure code [CA1977] Fuel Doser Open/Short Error ....2258
Failure code [CA1993] KDPF Delta Pressure Low Error ....2260
Failure code [CA2185] Throt Sensor Sup Volt High Error ....2262
Failure code [CA2186] Throt Sensor Sup Volt Low Error ....2264
Failure code [CA2249] Rail Press Very Low Error ....2266
Failure code [CA2265] Fuel Feed Pump Open Error ....2267
Failure code [CA2266] Fuel Feed Pump Short Error ....2269
Failure code [CA2271] EGR Valve Pos Sens High Error ....2271
Failure code [CA2272] EGR Valve Pos Sens Low Error ....2273
Failure code [CA2349] EGR Valve Solenoid Open Error ....2275
Failure code [CA2353] EGR Valve Solenoid Short Error ....2277
Failure code [CA2357] EGR Valve Servo Error ....2279
Failure code [CA2381] KVGT Pos Sens High Error ....2280
Failure code [CA2382] KVGT Pos Sens Low Error ....2282
Failure code [CA2383] KVGT Solenoid Open Error ....2284
Failure code [CA2386] KVGT Solenoid Short Error ....2286
Failure code [CA2387] KVGT Servo Error ....2288
Failure code [CA2555] Grid Htr Relay Volt Low Error ....2289
Failure code [CA2556] Grid Htr Relay Volt High Error ....2291
Failure code [CA2637] KDOC Face Plugging ....2293
Failure code [CA2639] Manual Stationary Regeneration Request ....2295
Failure code [CA2732] Dosing Fuel Valve 2 High Error ....2298
Failure code [CA2733] Dosing Fuel Valve 2 Low Error ....2300
Failure code [CA2741] Dosing Fuel Valve Swap Error ....2302
Failure code [CA2765] Inj Trim Data Error ....2304
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error ....2305
Failure code [CA2881] Dosing Fuel Pressure Low Error 1 ....2308
Failure code [CA3133] KDPF Outlet Press Sens High Error ....2313
Failure code [CA3134] KDPF Outlet Press Sens Low Error ....2315
Failure code [CA3135] KDPF Outlet Press Sens In Range Error ....2317
Failure code [CA3167] Fuel Doser Degradation ....2320
Failure code [CA3251] KDOC Inlet Temp High Error ....2323
Failure code [CA3253] KDOC Temp Error - Non Regeneration ....2326
Failure code [CA3254] KDOC Outlet Temp High Error 1 ....2329
Failure code [CA3255] KDPF Temp Error - Non Regeneration ....2332
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....2336
Failure code [CA3311] KDOC Outlet Temp High Error 2 ....2339
Failure code [CA3312] KDPF Outlet Temp High Error 2 ....2342
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ....2345
Failure code [CA3314] KDOC Inlet Temp Sens High Error ....2348
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ....2352
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ....2357
Failure code [CA3317] KDOC Outlet Temp Sens High Error ....2360
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ....2364
Failure code [CA3319] KDPF Outlet Temp Sens High Error ....2369
Failure code [CA3321] KDPF Outlet Temp Sens Low Error ....2373
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ....2376
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ....2381
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ....2383
Failure code [D150KA] Disconnection of Emerg. Steering Relay ....2385
Failure code [D150KB] Ground Fault of Emerg. Steering Relay ....2387
Failure code [D150KY] Hot Short of Emergency Steering Relay ....2389
Failure code [D160KA] Disconnection of Backup Lamp Relay Output ....2391
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output ....2393
Failure code [D160KY] Hot Short of Backup Lamp Relay Output ....2395
Failure code [D191KA] Disconnection of Neutral Output Relay ....2397
Failure code [D191KB] Ground Fault of Neutral Output Relay ....2399
Failure code [D191KY] Hot Short of Neutral Output Relay ....2401
Failure code [D192KA] Disconnection of ECSS Solenoid ....2403
Failure code [D192KB] Ground Fault of ECSS Solenoid ....2405
Failure code [D192KY] Hot Short of ECSS Solenoid ....2406
Failure code [D19JKZ] Personal Code Relay Abnormality ....2407
Failure code [D1E6KA] Disconnection of Parking Brake Relay ....2409
Failure code [D1E6KB] Ground Fault of Parking Brake Relay ....2411
Failure code [D1E6KY] Hot Short of Parking Brake Relay ....2413
Failure code [D5ZHKA] Failure of Key SW C Signal ....2415
Failure code [D5ZHKB] Key SW C Signal Short Circuit ....2417
Failure code [D5ZHKZ] Failure of Key SW C Signal ....2419
Failure code [D5ZHL6] Disconnection of Key SW C ....2421
Failure code [D811MC] KOMTRAX Error ....2423
Failure code [D862KA] GPS Antenna Open Circuit ....2424
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ....2425
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ....2427
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ....2429
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ....2430
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ....2432
Failure code [DAF0MB] Monitor ROM Abnormality ....2433
Failure code [DAF0MC] Monitor Error ....2434
Failure code [DAF3KK] Controller Power Source Low (MON) ....2435
Failure code [DAF8KB] Camera Power Supply Short Circuit ....2437
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit ....2438
Failure code [DAFGMC] GPS Module Error ....2440
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ....2441
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) ....2443
Failure code [DAFQKR] CAN2 Discon (Monitor) ....2445
Failure code [DAQ0KK] Controller Power Source Low (T/M) ....2446
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ....2449
Failure code [DAQ0MC] T/M Con Error ....2450
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) ....2451
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ....2453
Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay ....2456
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) ....2458
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) ....2459
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ....2461
Failure code [DAQQKR] CAN2 Discon (Transmission Con) ....2463
Failure code [DAQRKR] CAN1 Discon (Transmission Con) ....2464
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ....2465
Failure code [DAZ9KQ] A/C Model Selection Abnormality ....2466
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ....2467
Failure code [DB2QKR] CAN2 Discon (Engine Con) ....2468
Failure code [DB2RKR] CAN1 Discon (Engine Con) ....2473
Failure code [DB90KK] Drop in BBC Controller Main Power Source ....2478
Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) ....2480
Failure code [DB90MC] BBC Error ....2481
Failure code [DB91KA] Disconnection of Key SW ACC (BBC) ....2482
Failure code [DB92KK] Solenoid Power Source Low (BBC) ....2484
Failure code [DB95KX] Failure of 5 V Power Source 1 ....2486
Failure code [DB96KX] Failure of 5 V Power Source 2 ....2488
Failure code [DB99KQ] Inconsistency of Model Selection (BBC) ....2490
Failure code [DB9LKA] Operating Lamp Open Circuit (BBC) ....2491
Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) ....2493
Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) ....2495
Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) ....2496
Failure code [DB9RMA] Inconsistency of Option Selection (BBC) ....2497
Failure code [DBE5KX] Failure of 5V Power Source ....2498
Failure code [DBE6KX] Failure of 24 V Power Source ....2500
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ....2502
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ....2504
Failure code [DDB6L4] Neutral Signal Malfunction ....2506
Failure code [DDD1LD] Failure of Bucket Positioner Set Switch ....2509
Failure code [DDK3KA] FNR SW Input Signal Disconnection ....2511
Failure code [DDK3KB] FNR SW Input Signal Short Circuit ....2514
Failure code [DDK6KA] FNR Lever Input Signal Disconnection ....2516
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ....2519
Failure code [DDNRKY] Hot Short of Work Equipment Lock SW ....2521
Failure code [DDT0L4] Failure of Shift Mode Select SW ....2523
Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal ....2525
Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal ....2527
Failure code [DDW9LD] Ground Fault of Kickdown Switch ....2529
Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW ....2531
Failure code [DF10KA] Disconnection of Shift Lever Input ....2533
Failure code [DF10KB] Ground Fault of Shift Lever Input ....2535
Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor ....2538
Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor ....2540
Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor ....2542
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ....2544
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor ....2545
Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor ....2547
Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor ....2550
Failure code [DH21KA] Failure of Loader Pump Press. Sensor ....2552
Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit ....2554
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit ....2556
Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor ....2558
Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor ....2560
Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor ....2562
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor ....2564
Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor ....2566
Failure code [DHT8KA] Failure of Steering Pump Press. Sensor ....2568
Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit ....2570
Failure code [DHT8ZG] Steering Oil Pressure Low ....2572
Failure code [DHUDKA] Failure of Emrg. Steering Press. Sensor ....2573
Failure code [DHUDKB] Emrg. Steering Press. S. Short Circuit ....2575
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ....2577
Failure code [DK55KA] Failure of FNR Lever Potentio ....2579
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ....2582
Failure code [DK55L5] Failure of FNR Lever Potentio ....2584
Failure code [DK59KA] Failure of Boom Lever Potentio (Main) ....2585
Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) ....2588
Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree ....2591
Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub) ....2595
Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) ....2598
Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) ....2601
Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) ....2604
Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree ....2607
Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) ....2611
Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) ....2614
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ....2617
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ....2620
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ....2622
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) ....2625
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) ....2628
Failure code [DKA0KA] Failure of Boom Angle Sensor ....2630
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit ....2632
Failure code [DKA0L0] Boom Angle Sensor Dislocation ....2634
Failure code [DKA1KA] Failure of Bucket Angle Sensor ....2636
Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit ....2638
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor ....2640
Failure code [DLF1LC] Failure of T/M Input Speed Sensor ....2642
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor ....2644
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ....2646
Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main) ....2648
Failure code [DLT3LC] Failure of Output Speed Sensor (Main) ....2650
Failure code [DPQ1KR] LIN Discon (Switch Panel) ....2652
Failure code [DPQ2KR] LIN Discon (LED Unit) ....2655
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ....2658
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ....2661
Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator ....2663
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ....2665
Failure code [DV00KB] Ground Fault of Buzzer Output ....2667
Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) ....2669
Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise) ....2671
Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) ....2673
Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) ....2675
Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) ....2677
Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) ....2679
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ....2681
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) ....2683
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ....2685
Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) ....2687
Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) ....2689
Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) ....2691
Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid ....2693
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. ....2695
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. ....2697
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ....2698
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid ....2700
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ....2702
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ....2704
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ....2706
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ....2708
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ....2710
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ....2712
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ....2714
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. ....2716
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ....2718
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ....2720
Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid ....2722
Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid ....2724
Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid ....2726
Failure code [DXANKA] Disconnection of Steering Pump EPC Sol. ....2728
Failure code [DXANKB] Ground Fault of Steering Pump EPC Solenoid ....2730
Failure code [DXANKY] Hot Short of Steering Pump EPC Solenoid ....2732
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ....2733
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ....2735
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) ....2737
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) ....2739
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) ....2741
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) ....2743
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) ....2745
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) ....2747
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) ....2749
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ....2751
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) ....2753
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) ....2755
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) ....2757
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ....2759
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) ....2761
Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) ....2763
Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward) ....2765
Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) ....2767
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) ....2769
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) ....2771
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) ....2773
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ....2775
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) ....2777
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ....2779
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ....2781
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ....2783
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ....2785
Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor ....2787
Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor ....2790
Failure code [DY30ME] Emerg. Steering Long-Time Activated ....2794
Failure code [LA00L3] Failure of Fan Reverse ....2796
Troubleshooting of electrical system (E-mode) ....2797
E-1 Engine does not start ....2797
E-2 Manual preheating system does not work ....2803
E-3 Automatic preheating system does not work ....2806
E-4 While preheating is working, preheating monitor does not light up ....2808
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing ....2810
E-6 LCD unit on machine monitor displays nothing ....2813
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ....2815
E-8 LCD on machine monitor does not display properly ....2817
E-9 Meter unit display on machine monitor is abnormal ....2819
E-10 Night lighting lamp of meter unit on machine monitor is abnormal ....2822
E-11 Caution LED on machine monitor is abnormal ....2825
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ....2827
E-13 Two switches operation of switch panel on machine monitor does not function ....2829
E-14 Switch panel buzzer of machine monitor is abnormal ....2832
E-15 Rear view monitor does not light up or backlight flickers ....2834
E-16 Rear view monitor images are not displayed clearly ....2837
E-17 Rear view monitor brightness cannot be adjusted ....2840
E-18 Night lighting lamp of rear view monitor is abnormal ....2843
E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ....2845
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position ....2846
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light ....2850
E-22 Air cleaner clogging indicator lamp does not light ....2852
E-23 Radiator coolant level caution lamp does not light ....2853
E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil temperature caution lamp does not light ....2855
E-25 Indication of torque converter oil temperature gauge does not increase, or torque converter oil temperature caution lamp does not light ....2857
E-26 Fuel level gauge does not indicate correct level ....2858
E-27 Seat belt caution lamp indication is abnormal ....2860
E-28 Horn does not sound ....2861
E-29 Horn does not stop sounding ....2864
E-30 Alarm buzzer does not sound ....2866
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ....2867
E-32 Kickdown does not work when kickdown switch is turned ON ....2868
E-33 The hold switch does not work when it is pressed ....2870
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 ....2872
E-35 Transmission cut-off mode is not selected or not released ....2875
E-36 Transmission cut-off setting cannot be released ....2877
E-37 Directional selector (FNR) switch mode is not selected or not released ....2879
E-38 When operating engine power selection switch, engine power selection function does not operate properly ....2881
E-39 Flow of loader pump does not increase from the minimum rate ....2883
E-40 ECSS function cannot be selected or cannot be released ....2884
E-41 None of headlamp, clearance lamp, and tail lamp lights ....2886
E-42 Clearance lamp and tail lamp do not light up or go out ....2888
E-43 Both High and Low beams of headlamp do not light up or go out ....2891
E-44 Low beam of headlamp does not light up or go out ....2895
E-45 High beam of headlamp does not light up or go out ....2897
E-46 Front working lamp does not light up or go out ....2899
E-47 Rear working lamp does not light up or go out ....2902
E-48 All of turn signal lamps and hazard lamps do not light up or go out ....2905
E-49 Turn signal lamps do not light up or go out ....2908
E-50 Hazard lamp does not light up or go out ....2911
E-51 Brake lamp does not light or stays lighted ....2914
E-52 Backup lamp does not light up or does not go out ....2917
E-53 Backup buzzer does not sound or continues to sound ....2920
E-54 Front wiper does not operate ....2922
E-55 Rear wiper does not operate ....2925
E-56 Window washer does not operate ....2927
E-57 Fuel feed pump does not operate or stop automatically ....2930
E-58 KOMTRAX system does not operate properly ....2932
Troubleshooting of hydraulic and mechanical system (H-mode) ....2934
Information described in troubleshooting table (H-mode) ....2934
System chart of hydraulic and mechanical systems ....2935
Failure mode and cause table ....2938
H-1 Machine does not move off ....2946
H-2 Torque converter lockup clutch is not disengaged (engine stalls) ....2949
H-3 Torque converter lockup clutch is not engaged ....2950
H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift ....2951
H-5 Large shock is made when machine starts or gear is shifted ....2954
H-6 Machine starts or gear speed shifts with long time lag ....2956
H-7 Torque converter oil temperature is high ....2958
H-8 Machine does not turn ....2960
H-9 Turning response is poor ....2962
H-10 Steering wheel is heavy to turn ....2964
H-11 Machine sways or large shocks are made while machine turns ....2965
H-12 Turning radius differs between right and left turns ....2967
H-13 Wheel brakes do not work or are weak ....2968
H-14 Wheel brakes are not released or drag ....2970
H-15 Parking brake does not work or it is weak ....2971
H-16 Parking brake is not released or drags (including emergency release system) ....2972
H-17 Boom does not rise ....2973
H-18 Boom moves slow or boom lacks lifting force ....2975
H-19 Rising boom slows down at certain height ....2977
H-20 Lift cylinders do not serve to hold bucket on ground ....2978
H-21 Hydraulic drift of boom is large ....2979
H-22 Boom moves up and down during operation ....2980
H-23 Bucket does not tilt back ....2981
H-24 Bucket moves slow or lacks tilt-back force ....2983
H-25 Bucket decelerates during tilt-back operation ....2985
H-26 Bucket cylinder does not hold bucket on ground ....2986
H-27 Hydraulic drift of bucket is large ....2987
H-28 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) ....2988
H-29 Boom and bucket control levers do not move smoothly and are heavy to move ....2989
H-30 Operating work equipment causes engine speed to lower significantly or engine to stall ....2990
H-31 Large shocks are made when work equipment starts to move and stops ....2991
H-32 When certain work equipment stalls hydraulically, other work equipment moves ....2993
H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces ....2994
H-34 Bucket does not stop at the position which is set with remote bucket positioner ....2995
H-35 Fan speed is abnormal (too high or low, or fan does not rotate) ....2996
H-36 Unusual noise is heard from around fan ....2997
Troubleshooting of engine (S-mode) ....2998
Information mentioned in troubleshooting table (S mode) ....2998
S-1 When starting switch is turned to START position, engine is not cranked ....2999
S-2 The engine cranks but exhaust smoke does not come out ....3000
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) ....3001
S-4 Engine startability is poor ....3002
S-5 Engine does not pick-up smoothly ....3004
S-6 Engine stops during operation ....3006
S-7 Engine runs rough or is unstable ....3008
S-8 Engine lacks power ....3009
S-9 KDPF gets clogged in a short time ....3011
S-10 Engine oil consumption is excessive ....3013
S-11 Engine oil becomes contaminated early ....3014
S-12 Fuel consumption is excessive ....3015
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ....3016
S-14 Oil pressure drops ....3017
S-15 Fuel mixes into engine oil ....3018
S-16 Water mixes into engine oil (milky) ....3019
S-17 Coolant temperature rises too high (overheating) ....3020
S-18 Unusual noise is heard ....3021
S-19 Vibration is excessive ....3022
S-20 Air cannot be bled from fuel circuit ....3023
S-21 Active regeneration is executed frequently ....3024
S-22 Active regeneration takes a long time ....3025
S-23 White smoke is exhausted during active regeneration ....3026
50 Disassembly and assembly ....3028
Table of contents ....3029
General information on disassembly and assembly ....3031
How to read this manual ....3031
Coating materials list ....3033
Special tools list ....3037
Sketches of special tools ....3044
Engine and cooling system ....3074
Removal and installation of supply pump assembly ....3074
Removal and installation of injector assembly ....3080
Removal and installation of fuel doser assembly ....3088
Removal and installation of cylinder head assembly ....3090
Removal and installation of engine hood assembly ....3104
Removal and installation of grille assembly ....3106
Removal and installation of cooling system assembly ....3109
Removal and installation of radiator core assembly ....3112
Removal and installation of aftercooler ....3114
Removal and installation of hydraulic oil cooler ....3117
Removal and installation of power train oil cooler assembly ....3119
Removal and installation of engine assembly ....3123
Removal and installation of engine front oil seal ....3129
Removal and installation of engine rear oil seal ....3132
Removal and installation of cooling fan and cooling fan motor assembly ....3137
Removal and installation of KDPF assembly ....3139
Disassembly and assembly of KDPF assembly ....3144
Removal and installation of KCCV assembly ....3153
Removal and installation of KVGT assembly ....3155
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ....3160
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ....3161
Removal and installation of air cleaner assembly ....3163
Removal and installation of air conditioner compressor belt ....3165
Removal and installation of alternator belt ....3166
Removal and installation of fuel tank assembly ....3167
Power train ....3170
Removal and installation of torque converter and transmission assembly ....3170
Disassembly and assembly of transmission assembly ....3175
Disassembly and assembly of torque converter assembly ....3205
Disassembly and assembly of transmission clutch pack assembly ....3212
Removal and installation of front axle assembly ....3235
Removal and installation of rear axle assembly ....3237
Disassembly and assembly of axle housing assembly ....3242
Disassembly and assembly of differential assembly ....3252
Steering system ....3271
Removal and installation of steering valve assembly ....3271
Brake system ....3273
Removal and installation of brake charge valve assembly ....3273
Removal and installation of parking brake disc and plate ....3274
Undercarriage and frame ....3277
Removal and installation of center hinge pin ....3277
Removal and installation of counterweight assembly ....3285
Removal and installation of full-length fender assembly ....3287
Hydraulic system ....3288
Removal and installation of hydraulic tank assembly ....3288
Removal and installation of control valve assembly ....3291
Removal and installation of steering pump and power train pump assembly ....3294
Removal and installation of work equipment pump and cooling fan pump assembly ....3296
Disassembly and assembly of hydraulic cylinder assembly ....3298
Work equipment ....3305
Removal and installation of work equipment assembly ....3305
Cab and its attachments ....3310
Removal and installation of operator's cab and floor frame assembly ....3310
Removal and installation of operator's cab glass (stuck window glass) ....3314
Removal and installation of operator's seat assembly ....3322
Removal and installation of seat belt ....3324
Removal and installation of air conditioner unit assembly ....3325
Removal and installation of air conditioner compressor assembly ....3330
Removal and installation of air conditioner condenser assembly ....3332
Electrical system ....3334
Removal and installation of machine monitor assembly ....3334
Removal and installation of engine controller assembly ....3335
Removal and installation of work equipment controller assembly ....3336
Removal and installation of transmission controller assembly ....3338
Removal and installation of monitor controller assembly ....3339
Removal and installation of mass air flow and temperature sensor ....3341
Removal and installation of KOMTRAX terminal assembly ....3342
60 Maintenance standard ....3344
Table of contents ....3345
Engine and cooling system ....3346
Engine related parts ....3346
Cooling fan pump ....3347
Cooling fan motor ....3350
Power train ....3352
Drive shaft ....3352
Torque converter ....3353
Transmission ....3355
Transmission control valve ....3364
Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV ....3366
3rd, 4th clutch ECMV ....3367
Lockup clutch ECMV ....3368
Main relief and torque converter relief valve ....3369
Axle ....3370
Differential ....3372
Final drive ....3382
Steering system ....3384
Steering column ....3384
Steering pump ....3385
Steering valve ....3389
Steering cylinder ....3391
Emergency steering pump ....3394
Brake system ....3395
Charge valve ....3395
Slack adjuster ....3397
Brake ....3398
Parking brake ....3400
Parking brake solenoid valve ....3401
Undercarriage and frame ....3402
Axle mount and center hinge pin ....3402
Hydraulic system ....3406
Hydraulic tank ....3406
Double type gear pump ....3407
Work equipment pump ....3408
Control valve ....3410
Work equipment ....3419
Work equipment linkage ....3419
Bucket ....3423
Work equipment cylinder ....3424
80 Appendix ....3426
Table of contents ....3427
Air conditioner components ....3428
Precautions for refrigerant ....3428
Air conditioner component ....3429
Configuration and function of refrigeration cycle ....3431
Outline of refrigeration cycle ....3432
Air conditioner unit ....3434
Dual pressure switch ....3439
Air conditioner controller ....3440
Compressor ....3441
Condenser ....3442
Receiver drier ....3443
Sunlight sensor ....3445
Outer temperature sensor (outside air temperature sensor) ....3446
Procedure for testing and troubleshooting ....3447
Circuit diagram and arrangement of connector pins ....3449
System diagram ....3452
Parts and connectors layout ....3455
Testing with self-diagnosis function ....3460
How to open the electrical system abnormality record screen in service mode of the machine monitor ....3461
Testing temperature control system ....3463
Testing vent (mode) changeover ....3465
Testing FRESH/RECIRC air changeover ....3467
Check evaporator temperature sensor ....3469
Testing relays ....3471
Troubleshooting chart 1 ....3473
Troubleshooting chart 2 ....3474
Information in troubleshooting table ....3476
Failure code list related to air conditioner ....3477
Failure code [879AKA] A/C Inner Sensor Open Circuit ....3478
Failure code [879AKB] A/C Inner Sensor Short Circuit ....3480
Failure code [879BKA] A/C Outer Sensor Open Circuit ....3482
Failure code [879BKB] A/C Outer Sensor Short Circuit ....3484
Failure code [879CKA] Ventilating Sensor Open Circuit ....3486
Failure code [879CKB] Ventilating Sensor Short Circuit ....3488
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ....3490
Failure code [879EMC] Ventilation Damper Abnormality ....3492
Failure code [879FMC] Air Mix Damper Abnormality ....3495
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) ....3498
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ....3501
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ....3504
A-4 Troubleshooting for FRESH/RECIRC air changeover ....3507
Troubleshooting with gauge pressure ....3509
Connection of service tool ....3512
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ....3514
Handling of compressor oil ....3516
90 Diagrams and drawings ....3518
Table of contents ....3519
Hydraulic circuit diagram ....3520
Symbols in hydraulic circuit diagram ....3520
Hydraulic circuit diagram of power train ....3524
Electric circuit diagram ....3527
Symbols in electric circuit diagram ....3527
CEBM027201 - Wheel Loader WA470-7 Shop Manual....3556
CEBM027200 - WA470-7 s/n A47001 - and up....0
00 Index and foreword ....3558
Index ....3559
Foreword, safety and general information ....3575
Important safety notice ....3575
How to read the shop manual ....3582
Explanation of terms for maintenance standard ....3584
Handling equipment of fuel system devices ....3586
Handling of intake system parts ....3587
Handling of hydraulic equipment ....3588
Method of disconnecting and connecting of push-pull type coupler ....3590
Handling of electrical equipment ....3593
How to read electric wire code ....3601
Precautions when performing operation ....3604
Practical use of KOMTRAX ....3608
Standard tightening torque table ....3609
List of abbreviation ....3613
Conversion table ....3618
01 Specification ....3624
Table of contents ....3625
Specifications ....3626
Specification drawing ....3626
Specifications ....3628
Weight table ....3634
Table of fuel, coolant, and lubricants ....3636
10 Structure and function ....3638
Table of contents ....3639
Engine and cooling system ....3641
Engine related parts ....3641
KVGT ....3643
EGR system piping drawing ....3649
EGR system circuit diagram ....3651
EGR valve ....3652
EGR cooler ....3654
KCCV layout drawing ....3656
KCCV ventilator ....3658
KDPF ....3660
Cooling system ....3664
Cooling fan pump ....3667
Cooling fan motor ....3676
Power train ....3683
Power train system ....3683
Drive shaft ....3686
Power train piping drawing ....3687
Transmission control ....3688
Torque converter ....3691
Transmission ....3696
Transmission control valve ....3715
Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV ....3718
3rd, 4th clutch ECMV ....3725
Lockup clutch ECMV ....3732
Main relief and torque converter relief valve ....3736
Axle ....3738
Differential ....3740
Final drive ....3750
Steering system ....3752
Layout of steering parts ....3752
Steering column ....3753
Steering pump ....3754
Steering valve ....3766
Orbit-roll valve ....3780
Stop valve ....3786
Emergency steering motor ....3787
Emergency steering pump ....3788
Brake system ....3789
Layout of brake parts ....3789
Charge valve ....3791
Brake valve ....3797
Slack adjuster ....3801
Accumulator (for brake) ....3804
Brake ....3805
Parking brake control ....3808
Parking brake ....3809
Parking brake solenoid valve ....3810
Parking brake emergency release valve ....3813
Undercarriage and frame ....3814
Axle mount and center hinge pin ....3814
Tire ....3815
Hydraulic system ....3817
Hydraulic component layout ....3817
Work equipment control ....3819
Hydraulic tank ....3820
Double type gear pump ....3823
Work equipment pump ....3824
Control valve ....3845
CLSS ....3854
Hydraulic circuit diagram and names of valves ....3858
Accumulator charge valve ....3869
Work equipment lock solenoid valve ....3873
Accumulator (for PPC circuit) ....3874
Accumulator (for ECSS) ....3875
Work equipment ....3876
Work equipment linkage ....3876
Bucket ....3877
Bucket positioner and boom positioner ....3878
Cab and its attachments ....3879
ROPS cab ....3879
Electrical system ....3880
Engine control system ....3880
Preheating system ....3882
Engine power mode selector circuit ....3884
Engine output limit function ....3885
Automatic warm-up function ....3886
Parking brake control system ....3887
System operating lamp function ....3889
Battery disconnect switch function ....3891
Transmission controller system ....3893
Work equipment control system ....3914
Machine monitor system ....3930
Rear view monitor system ....3954
KOMTRAX system ....3957
System component parts ....3960
Sensor ....3987
20 Standard value tables ....4016
Table of contents ....4017
Standard service value table ....4018
Standard value table for engine ....4018
Standard value table for machine ....4020
Standard value table for electrical system ....4033
30 Testing and adjusting ....4048
Table of contents ....4049
General information on testing and adjusting ....4051
Tools for testing and adjusting ....4051
Sketch of tools for testing and adjusting ....4055
Engine and cooling system ....4057
Testing engine speed ....4057
Testing boost pressure ....4059
Testing exhaust gas color ....4061
Testing and adjusting valve clearance ....4063
Testing compression pressure ....4065
Testing blowby pressure ....4069
Testing engine oil pressure ....4071
Testing EGR valve and KVGT oil pressures ....4072
Testing fuel pressure ....4073
Testing fuel return rate and leakage ....4074
Bleeding air from fuel system ....4078
Testing fuel circuit for leakage ....4080
Handling cylinder cutout mode operation ....4081
Handling no injection cranking operation ....4082
Testing of KDPF and muffler stack for looseness and damage ....4083
Testing of installed condition of cylinder head and manifolds ....4084
Testing engine piping for damage and looseness ....4085
Testing and adjusting air conditioner compressor belt tension ....4086
Testing and adjusting alternator belt tension ....4088
Procedures for cleaning fuel doser ....4090
Writing compensation values at replacement of injector and engine controller ....4093
Power train ....4097
Adjusting transmission output speed sensor ....4097
Adjusting transmission input speed sensor ....4098
Flushing procedure for torque converter and transmission hydraulic circuit ....4099
Retrieval of disabled machine due to transmission valve failure ....4101
Testing oil leakage from axle final drive ....4103
Testing drive shaft for looseness, backlash, and damage ....4104
Testing and adjusting power train oil pressure ....4105
Steering system ....4120
Testing directional lever ....4120
Testing steering wheel ....4121
Testing work equipment control lever ....4123
Testing and adjusting steering circuit oil pressure ....4125
Bleeding air from steering cylinder circuit. ....4128
Testing and adjusting steering stopper valve ....4129
Brake system ....4130
Testing brake pedal ....4130
Testing and adjusting brake pedal linkage ....4131
Testing braking performance ....4132
Testing and adjusting of accumulator charge pressure ....4133
Testing of brake accumulator nitrogen gas pressure and procedure for charging brake accumulator with nitrogen gas ....4135
Testing wheel brake oil pressure ....4139
Testing lowering of wheel brake pressure ....4141
Testing wear of wheel brake disc ....4143
Bleeding air from wheel brake circuit ....4144
Releasing remaining pressure in brake accumulator circuit ....4146
Testing parking brake performance ....4147
Testing parking brake oil pressure ....4148
Testing wear of parking brake disc ....4149
Method of releasing parking brake manually ....4150
Hydraulic system ....4152
Testing fan speed ....4152
Testing fan pump circuit oil pressure ....4153
Bleeding air from hydraulic fan circuit ....4155
Testing and adjusting work equipment EPC oil pressure ....4157
Testing and adjusting work equipment oil pressure ....4160
Bleeding air from work equipment circuit ....4164
Releasing remaining pressure from work equipment circuit ....4165
Testing of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ....4166
Work equipment ....4170
Testing and adjusting bucket position detection lever ....4170
Testing and adjusting boom position detection lever ....4171
Electrical system ....4172
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ....4172
Special functions of machine monitor ....4174
Adjusting rearview camera angle ....4263
Handling voltage circuit of engine controller ....4264
Handling battery disconnect switch ....4265
Testing diodes ....4266
Pm clinic ....4267
Pm Clinic service ....4267
Check sheet ....4268
40 Troubleshooting ....4274
Table of contents ....4275
General information on troubleshooting ....4284
Troubleshooting points ....4284
Sequence of events in troubleshooting ....4286
Check before troubleshooting ....4288
Inspection procedure before troubleshooting ....4290
Preparation work for troubleshooting of electrical system ....4307
Classification and procedures for troubleshooting ....4313
Symptom and troubleshooting numbers ....4316
Information in troubleshooting table ....4319
Connector list and layout ....4321
Connector contact identification ....4335
T-branch box and T-branch adapter table ....4371
Fuse location table ....4377
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ....4380
Precautions on troubleshooting of machine monitor ....4383
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ....4385
Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors) ....4390
Fabrication of short-circuit connector (for CA1883 and CA3135) ....4391
Failure codes table ....4392
Troubleshooting by failure code (Display of code) ....4406
Failure code [1500L0] Double Engagement of T/M Clutches ....4406
Failure code [15SAL1] Release Trouble of ECMV (Forward) ....4407
Failure code [15SALH] Malfunction of ECMV (Forward) ....4409
Failure code [15SBL1] Release Trouble of ECMV (Reverse) ....4411
Failure code [15SBLH] Malfunction of ECMV (Reverse) ....4413
Failure code [15SEL1] Release Trouble of ECMV (1st) ....4415
Failure code [15SELH] Malfunction of ECMV (1st) ....4417
Failure code [15SFL1] Release Trouble of ECMV (2nd) ....4419
Failure code [15SFLH] Malfunction of ECMV (2nd) ....4421
Failure code [15SGL1] Release Trouble of ECMV (3rd) ....4423
Failure code [15SGLH] Malfunction of ECMV (3rd) ....4425
Failure code [15SHL1] Release Trouble of ECMV (4th) ....4427
Failure code [15SHLH] Malfunction of ECMV (4th) ....4429
Failure code [2F00MA] Failure of Parking Brake Circuit ....4431
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ....4435
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ....4437
Failure code [879AKA] A/C Inner Sensor Open Circuit ....4439
Failure code [879AKB] A/C Inner Sensor Short Circuit ....4440
Failure code [879BKA] A/C Outer Sensor Open Circuit ....4441
Failure code [879BKB] A/C Outer Sensor Short Circuit ....4442
Failure code [879CKA] Ventilating Sensor Open Circuit ....4443
Failure code [879CKB] Ventilating Sensor Short Circuit ....4444
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ....4445
Failure code [879EMC] Ventilation Damper Abnormality ....4446
Failure code [879FMC] Air Mix Damper Abnormality ....4447
Failure code [989A00] Engine Overrun Prevention Activated ....4448
Failure code [989L00] Engine Controller Lock Caution 1 ....4449
Failure code [989M00] Engine Controller Lock Caution 2 ....4450
Failure code [989N00] Engine Controller Lock Caution 3 ....4451
Failure code [A1U0N3] HC Desorb Request 1 ....4452
Failure code [A1U0N4] HC Desorb Request 2 ....4454
Failure code [AA10NX] Air Cleaner Clogging ....4456
Failure code [B@BAZG] Eng Oil Press Low ....4458
Failure code [B@BAZK] Eng Oil Level Low ....4459
Failure code [B@BCNS] Eng Water Overheat ....4461
Failure code [B@BCZK] Eng Water Level Low ....4462
Failure code [B@CENS] T/C Oil Temp. Overheat ....4464
Failure code [B@HANS] HYD Oil Temp. Overheat ....4465
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ....4466
Failure code [CA122] Chg Air Press Sensor High Error ....4467
Failure code [CA123] Chg Air Press Sensor Low Error ....4469
Failure code [CA131] Throttle Sensor High Error ....4471
Failure code [CA132] Throttle Sensor Low Error ....4473
Failure code [CA135] Eng Oil Press Sensor High Error ....4475
Failure code [CA141] Eng Oil Press Sensor Low Error ....4477
Failure code [CA144] Coolant Temp Sens High Error ....4479
Failure code [CA145] Coolant Temp Sens Low Error ....4481
Failure code [CA153] Chg Air Temp Sensor High Error ....4483
Failure code [CA154] Chg Air Temp Sensor Low Error ....4485
Failure code [CA187] Sensor 2 Supply Volt Low Error ....4487
Failure code [CA221] Ambient Press Sensor High Error ....4489
Failure code [CA222] Ambient Press Sensor Low Error ....4491
Failure code [CA227] Sensor 2 Supply Volt High Error ....4493
Failure code [CA234] Eng Overspeed ....4494
Failure code [CA238] Ne Speed Sensor Supply Volt Error ....4495
Failure code [CA239] Ne Speed Sens Supply Volt High Error ....4496
Failure code [CA271] IMV/PCV1 Short Error ....4497
Failure code [CA272] IMV/PCV1 Open Error ....4498
Failure code [CA273] PCV2 Short Error ....4499
Failure code [CA274] PCV2 Open Error ....4500
Failure code [CA322] Inj #1(L#1) Open/Short Error ....4501
Failure code [CA323] Inj #5(L#5) Open/Short Error ....4503
Failure code [CA324] Inj #3(L#3) Open/Short Error ....4505
Failure code [CA325] Inj #6(L#6) Open/Short Error ....4507
Failure code [CA331] Inj #2(L#2) Open/Short Error ....4509
Failure code [CA332] Inj #4(L#4) Open/Short Error ....4511
Failure code [CA343] ECM Critical Internal Failure ....4513
Failure code [CA351] Injectors Drive Circuit Error ....4514
Failure code [CA352] Sensor 1 Supply Volt Low Error ....4515
Failure code [CA356] Mass Air Flow Sensor High Error ....4517
Failure code [CA357] Mass Air Flow Sensor Low Error ....4519
Failure code [CA386] Sensor 1 Supply Volt High Error ....4521
Failure code [CA431] Idle Validation Sw Error ....4522
Failure code [CA432] Idle Validation Process Error ....4525
Failure code [CA441] Battery Voltage Low Error ....4528
Failure code [CA442] Battery Voltage High Error ....4530
Failure code [CA449] Rail Press Very High Error ....4531
Failure code [CA451] Rail Press Sensor High Error ....4532
Failure code [CA452] Rail Press Sensor Low Error ....4534
Failure code [CA515] Rail Press Sens Sup Volt High Error ....4536
Failure code [CA516] Rail Press Sens Sup Volt Low Error ....4538
Failure code [CA553] Rail Press High Error ....4540
Failure code [CA555] Crankcase Press High Error 1 ....4541
Failure code [CA556] Crankcase Press High Error 2 ....4542
Failure code [CA559] Rail Press Low Error ....4543
Failure code [CA595] Turbo Speed High Error 2 ....4547
Failure code [CA687] Turbo Speed Low Error ....4548
Failure code [CA689] Eng Ne Speed Sensor Error ....4550
Failure code [CA691] Intake Air Temp Sens High Error ....4552
Failure code [CA692] Intake Air Temp Sens Low Error ....4554
Failure code [CA697] ECM Internal Temp Sensor High Error ....4556
Failure code [CA698] ECM Int Temp Sensor Low Error ....4557
Failure code [CA731] Eng Bkup Speed Sens Phase Error ....4558
Failure code [CA778] Eng Bkup Speed Sensor Error ....4559
Failure code [CA1117] Persistent Data Lost Error ....4561
Failure code [CA1664] KDOC Malfunction ....4562
Failure code [CA1691] Regeneration Ineffective ....4565
Failure code [CA1695] Sensor 5 Supply Volt High Error ....4568
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....4569
Failure code [CA1843] Crankcase Press Sens High Error ....4571
Failure code [CA1844] Crankcase Press Sens Low Error ....4573
Failure code [CA1879] KDPF Delta P Sensor High Error ....4575
Failure code [CA1881] KDPF Delta P Sensor Low Error ....4577
Failure code [CA1883] KDPF Delta P Sens In Range Error ....4579
Failure code [CA1921] KDPF Soot Load High Error 1 ....4582
Failure code [CA1922] KDPF Soot Load High Error 2 ....4585
Failure code [CA1923] Dosing Fuel Valve 1 High Error ....4590
Failure code [CA1924] Dosing Fuel Valve 1 Low Error ....4592
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ....4595
Failure code [CA1927] Dosing Fuel Press Sens High Error ....4597
Failure code [CA1928] Dosing Fuel Press Sens Low Error ....4599
Failure code [CA1942] Crankcase Press Sens In Range Error ....4601
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ....4602
Failure code [CA1977] Fuel Doser Open/Short Error ....4604
Failure code [CA1993] KDPF Delta Pressure Low Error ....4606
Failure code [CA2185] Throt Sensor Sup Volt High Error ....4608
Failure code [CA2186] Throt Sensor Sup Volt Low Error ....4610
Failure code [CA2249] Rail Press Very Low Error ....4612
Failure code [CA2265] Fuel Feed Pump Open Error ....4613
Failure code [CA2266] Fuel Feed Pump Short Error ....4615
Failure code [CA2271] EGR Valve Pos Sens High Error ....4617
Failure code [CA2272] EGR Valve Pos Sens Low Error ....4619
Failure code [CA2349] EGR Valve Solenoid Open Error ....4621
Failure code [CA2353] EGR Valve Solenoid Short Error ....4623
Failure code [CA2357] EGR Valve Servo Error ....4625
Failure code [CA2381] KVGT Pos Sens High Error ....4626
Failure code [CA2382] KVGT Pos Sens Low Error ....4628
Failure code [CA2383] KVGT Solenoid Open Error ....4630
Failure code [CA2386] KVGT Solenoid Short Error ....4632
Failure code [CA2387] KVGT Servo Error ....4634
Failure code [CA2555] Grid Htr Relay Volt Low Error ....4635
Failure code [CA2556] Grid Htr Relay Volt High Error ....4637
Failure code [CA2637] KDOC Face Plugging ....4639
Failure code [CA2639] Manual Stationary Regeneration Request ....4641
Failure code [CA2732] Dosing Fuel Valve 2 High Error ....4644
Failure code [CA2733] Dosing Fuel Valve 2 Low Error ....4646
Failure code [CA2741] Dosing Fuel Valve Swap Error ....4648
Failure code [CA2765] Inj Trim Data Error ....4650
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error ....4651
Failure code [CA2881] Dosing Fuel Pressure Low Error 1 ....4654
Failure code [CA3133] KDPF Outlet Press Sens High Error ....4659
Failure code [CA3134] KDPF Outlet Press Sens Low Error ....4661
Failure code [CA3135] KDPF Outlet Press Sens In Range Error ....4663
Failure code [CA3167] Fuel Doser Degradation ....4666
Failure code [CA3251] KDOC Inlet Temp High Error ....4669
Failure code [CA3253] KDOC Temp Error - Non Regeneration ....4672
Failure code [CA3254] KDOC Outlet Temp High Error 1 ....4675
Failure code [CA3255] KDPF Temp Error - Non Regeneration ....4678
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....4682
Failure code [CA3311] KDOC Outlet Temp High Error 2 ....4685
Failure code [CA3312] KDPF Outlet Temp High Error 2 ....4688
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ....4691
Failure code [CA3314] KDOC Inlet Temp Sens High Error ....4694
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ....4698
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ....4703
Failure code [CA3317] KDOC Outlet Temp Sens High Error ....4706
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ....4710
Failure code [CA3319] KDPF Outlet Temp Sens High Error ....4715
Failure code [CA3321] KDPF Outlet Temp Sens Low Error ....4719
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ....4722
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ....4727
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ....4729
Failure code [D150KA] Disconnection of Emerg. Steering Relay ....4731
Failure code [D150KB] Ground Fault of Emerg. Steering Relay ....4733
Failure code [D150KY] Hot Short of Emergency Steering Relay ....4735
Failure code [D160KA] Disconnection of Backup Lamp Relay Output ....4737
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output ....4739
Failure code [D160KY] Hot Short of Backup Lamp Relay Output ....4741
Failure code [D191KA] Disconnection of Neutral Output Relay ....4743
Failure code [D191KB] Ground Fault of Neutral Output Relay ....4745
Failure code [D191KY] Hot Short of Neutral Output Relay ....4747
Failure code [D192KA] Disconnection of ECSS Solenoid ....4749
Failure code [D192KB] Ground Fault of ECSS Solenoid ....4751
Failure code [D192KY] Hot Short of ECSS Solenoid ....4752
Failure code [D19JKZ] Personal Code Relay Abnormality ....4753
Failure code [D1E6KA] Disconnection of Parking Brake Relay ....4755
Failure code [D1E6KB] Ground Fault of Parking Brake Relay ....4757
Failure code [D1E6KY] Hot Short of Parking Brake Relay ....4759
Failure code [D5ZHKA] Failure of Key SW C Signal ....4761
Failure code [D5ZHKB] Key SW C Signal Short Circuit ....4763
Failure code [D5ZHKZ] Failure of Key SW C Signal ....4765
Failure code [D5ZHL6] Disconnection of Key SW C ....4767
Failure code [D811MC] KOMTRAX Error ....4769
Failure code [D862KA] GPS Antenna Open Circuit ....4770
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ....4771
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ....4773
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ....4775
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ....4776
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ....4778
Failure code [DAF0MB] Monitor ROM Abnormality ....4779
Failure code [DAF0MC] Monitor Error ....4780
Failure code [DAF3KK] Controller Power Source Low (MON) ....4781
Failure code [DAF8KB] Camera Power Supply Short Circuit ....4783
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit ....4784
Failure code [DAFGMC] GPS Module Error ....4786
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ....4787
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) ....4789
Failure code [DAFQKR] CAN2 Discon (Monitor) ....4791
Failure code [DAQ0KK] Controller Power Source Low (T/M) ....4792
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ....4795
Failure code [DAQ0MC] T/M Con Error ....4796
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) ....4797
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ....4799
Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay ....4802
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) ....4804
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) ....4805
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ....4807
Failure code [DAQQKR] CAN2 Discon (Transmission Con) ....4809
Failure code [DAQRKR] CAN1 Discon (Transmission Con) ....4810
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ....4811
Failure code [DAZ9KQ] A/C Model Selection Abnormality ....4812
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ....4813
Failure code [DB2QKR] CAN2 Discon (Engine Con) ....4814
Failure code [DB2RKR] CAN1 Discon (Engine Con) ....4819
Failure code [DB90KK] Drop in BBC Controller Main Power Source ....4824
Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) ....4826
Failure code [DB90MC] BBC Error ....4827
Failure code [DB91KA] Disconnection of Key SW ACC (BBC) ....4828
Failure code [DB92KK] Solenoid Power Source Low (BBC) ....4830
Failure code [DB95KX] Failure of 5 V Power Source 1 ....4832
Failure code [DB96KX] Failure of 5 V Power Source 2 ....4834
Failure code [DB99KQ] Inconsistency of Model Selection (BBC) ....4836
Failure code [DB9LKA] Operating Lamp Open Circuit (BBC) ....4837
Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) ....4839
Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) ....4841
Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) ....4842
Failure code [DB9RMA] Inconsistency of Option Selection (BBC) ....4843
Failure code [DBE5KX] Failure of 5V Power Source ....4844
Failure code [DBE6KX] Failure of 24 V Power Source ....4846
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ....4848
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ....4850
Failure code [DDB6L4] Neutral Signal Malfunction ....4852
Failure code [DDD1LD] Failure of Bucket Positioner Set Switch ....4855
Failure code [DDK3KA] FNR SW Input Signal Disconnection ....4857
Failure code [DDK3KB] FNR SW Input Signal Short Circuit ....4860
Failure code [DDK6KA] FNR Lever Input Signal Disconnection ....4862
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ....4865
Failure code [DDNRKY] Hot Short of Work Equipment Lock SW ....4867
Failure code [DDT0L4] Failure of Shift Mode Select SW ....4869
Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal ....4871
Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal ....4873
Failure code [DDW9LD] Ground Fault of Kickdown Switch ....4875
Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW ....4877
Failure code [DF10KA] Disconnection of Shift Lever Input ....4879
Failure code [DF10KB] Ground Fault of Shift Lever Input ....4881
Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor ....4884
Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor ....4886
Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor ....4888
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ....4890
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor ....4891
Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor ....4893
Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor ....4896
Failure code [DH21KA] Failure of Loader Pump Press. Sensor ....4898
Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit ....4900
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit ....4902
Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor ....4904
Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor ....4906
Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor ....4908
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor ....4910
Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor ....4912
Failure code [DHT8KA] Failure of Steering Pump Press. Sensor ....4914
Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit ....4916
Failure code [DHT8ZG] Steering Oil Pressure Low ....4918
Failure code [DHUDKA] Failure of Emrg. Steering Press. Sensor ....4919
Failure code [DHUDKB] Emrg. Steering Press. S. Short Circuit ....4921
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ....4923
Failure code [DK55KA] Failure of FNR Lever Potentio ....4925
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ....4928
Failure code [DK55L5] Failure of FNR Lever Potentio ....4930
Failure code [DK59KA] Failure of Boom Lever Potentio (Main) ....4931
Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) ....4934
Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree ....4937
Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub) ....4941
Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) ....4944
Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) ....4947
Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) ....4950
Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree ....4953
Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) ....4957
Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) ....4960
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ....4963
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ....4966
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ....4968
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) ....4971
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) ....4974
Failure code [DKA0KA] Failure of Boom Angle Sensor ....4976
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit ....4978
Failure code [DKA0L0] Boom Angle Sensor Dislocation ....4980
Failure code [DKA1KA] Failure of Bucket Angle Sensor ....4982
Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit ....4984
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor ....4986
Failure code [DLF1LC] Failure of T/M Input Speed Sensor ....4988
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor ....4990
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ....4992
Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main) ....4994
Failure code [DLT3LC] Failure of Output Speed Sensor (Main) ....4996
Failure code [DPQ1KR] LIN Discon (Switch Panel) ....4998
Failure code [DPQ2KR] LIN Discon (LED Unit) ....5001
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ....5004
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ....5007
Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator ....5009
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ....5011
Failure code [DV00KB] Ground Fault of Buzzer Output ....5013
Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) ....5015
Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise) ....5017
Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) ....5019
Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) ....5021
Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) ....5023
Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) ....5025
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ....5027
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) ....5029
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ....5031
Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) ....5033
Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) ....5035
Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) ....5037
Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid ....5039
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. ....5041
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. ....5043
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ....5044
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid ....5046
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ....5048
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ....5050
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ....5052
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ....5054
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ....5056
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ....5058
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ....5060
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. ....5062
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ....5064
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ....5066
Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid ....5068
Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid ....5070
Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid ....5072
Failure code [DXANKA] Disconnection of Steering Pump EPC Sol. ....5074
Failure code [DXANKB] Ground Fault of Steering Pump EPC Solenoid ....5076
Failure code [DXANKY] Hot Short of Steering Pump EPC Solenoid ....5078
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ....5079
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ....5081
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) ....5083
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) ....5085
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) ....5087
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) ....5089
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) ....5091
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) ....5093
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) ....5095
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ....5097
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) ....5099
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) ....5101
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) ....5103
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ....5105
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) ....5107
Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) ....5109
Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward) ....5111
Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) ....5113
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) ....5115
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) ....5117
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) ....5119
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ....5121
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) ....5123
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ....5125
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ....5127
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ....5129
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ....5131
Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor ....5133
Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor ....5136
Failure code [DY30ME] Emerg. Steering Long-Time Activated ....5140
Failure code [LA00L3] Failure of Fan Reverse ....5142
Troubleshooting of electrical system (E-mode) ....5143
E-1 Engine does not start ....5143
E-2 Manual preheating system does not work ....5149
E-3 Automatic preheating system does not work ....5152
E-4 While preheating is working, preheating monitor does not light up ....5154
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing ....5156
E-6 LCD unit on machine monitor displays nothing ....5159
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ....5161
E-8 LCD on machine monitor does not display properly ....5163
E-9 Meter unit display on machine monitor is abnormal ....5165
E-10 Night lighting lamp of meter unit on machine monitor is abnormal ....5168
E-11 Caution LED on machine monitor is abnormal ....5171
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ....5173
E-13 Two switches operation of switch panel on machine monitor does not function ....5175
E-14 Switch panel buzzer of machine monitor is abnormal ....5178
E-15 Rear view monitor does not light up or backlight flickers ....5180
E-16 Rear view monitor images are not displayed clearly ....5183
E-17 Rear view monitor brightness cannot be adjusted ....5186
E-18 Night lighting lamp of rear view monitor is abnormal ....5189
E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ....5191
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position ....5192
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light ....5196
E-22 Air cleaner clogging indicator lamp does not light ....5198
E-23 Radiator coolant level caution lamp does not light ....5199
E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil temperature caution lamp does not light ....5201
E-25 Indication of torque converter oil temperature gauge does not increase, or torque converter oil temperature caution lamp does not light ....5203
E-26 Fuel level gauge does not indicate correct level ....5204
E-27 Seat belt caution lamp indication is abnormal ....5206
E-28 Horn does not sound ....5207
E-29 Horn does not stop sounding ....5210
E-30 Alarm buzzer does not sound ....5212
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ....5213
E-32 Kickdown does not work when kickdown switch is turned ON ....5214
E-33 The hold switch does not work when it is pressed ....5216
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 ....5218
E-35 Transmission cut-off mode is not selected or not released ....5221
E-36 Transmission cut-off setting cannot be released ....5223
E-37 Directional selector (FNR) switch mode is not selected or not released ....5225
E-38 When operating engine power selection switch, engine power selection function does not operate properly ....5227
E-39 Flow of loader pump does not increase from the minimum rate ....5229
E-40 ECSS function cannot be selected or cannot be released ....5230
E-41 None of headlamp, clearance lamp, and tail lamp lights ....5232
E-42 Clearance lamp and tail lamp do not light up or go out ....5234
E-43 Both High and Low beams of headlamp do not light up or go out ....5237
E-44 Low beam of headlamp does not light up or go out ....5241
E-45 High beam of headlamp does not light up or go out ....5243
E-46 Front working lamp does not light up or go out ....5245
E-47 Rear working lamp does not light up or go out ....5248
E-48 All of turn signal lamps and hazard lamps do not light up or go out ....5251
E-49 Turn signal lamps do not light up or go out ....5254
E-50 Hazard lamp does not light up or go out ....5257
E-51 Brake lamp does not light or stays lighted ....5260
E-52 Backup lamp does not light up or does not go out ....5263
E-53 Backup buzzer does not sound or continues to sound ....5266
E-54 Front wiper does not operate ....5268
E-55 Rear wiper does not operate ....5271
E-56 Window washer does not operate ....5273
E-57 Fuel feed pump does not operate or stop automatically ....5276
E-58 KOMTRAX system does not operate properly ....5278
Troubleshooting of hydraulic and mechanical system (H-mode) ....5280
Information described in troubleshooting table (H-mode) ....5280
System chart of hydraulic and mechanical systems ....5281
Failure mode and cause table ....5284
H-1 Machine does not move off ....5292
H-2 Torque converter lockup clutch is not disengaged (engine stalls) ....5295
H-3 Torque converter lockup clutch is not engaged ....5296
H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift ....5297
H-5 Large shock is made when machine starts or gear is shifted ....5300
H-6 Machine starts or gear speed shifts with long time lag ....5302
H-7 Torque converter oil temperature is high ....5304
H-8 Machine does not turn ....5306
H-9 Turning response is poor ....5308
H-10 Steering wheel is heavy to turn ....5310
H-11 Machine sways or large shocks are made while machine turns ....5311
H-12 Turning radius differs between right and left turns ....5313
H-13 Wheel brakes do not work or are weak ....5314
H-14 Wheel brakes are not released or drag ....5316
H-15 Parking brake does not work or it is weak ....5317
H-16 Parking brake is not released or drags (including emergency release system) ....5318
H-17 Boom does not rise ....5319
H-18 Boom moves slow or boom lacks lifting force ....5321
H-19 Rising boom slows down at certain height ....5323
H-20 Lift cylinders do not serve to hold bucket on ground ....5324
H-21 Hydraulic drift of boom is large ....5325
H-22 Boom moves up and down during operation ....5326
H-23 Bucket does not tilt back ....5327
H-24 Bucket moves slow or lacks tilt-back force ....5329
H-25 Bucket decelerates during tilt-back operation ....5331
H-26 Bucket cylinder does not hold bucket on ground ....5332
H-27 Hydraulic drift of bucket is large ....5333
H-28 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) ....5334
H-29 Boom and bucket control levers do not move smoothly and are heavy to move ....5335
H-30 Operating work equipment causes engine speed to lower significantly or engine to stall ....5336
H-31 Large shocks are made when work equipment starts to move and stops ....5337
H-32 When certain work equipment stalls hydraulically, other work equipment moves ....5339
H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces ....5340
H-34 Bucket does not stop at the position which is set with remote bucket positioner ....5341
H-35 Fan speed is abnormal (too high or low, or fan does not rotate) ....5342
H-36 Unusual noise is heard from around fan ....5343
Troubleshooting of engine (S-mode) ....5344
Information mentioned in troubleshooting table (S mode) ....5344
S-1 When starting switch is turned to START position, engine is not cranked ....5345
S-2 The engine cranks but exhaust smoke does not come out ....5346
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) ....5347
S-4 Engine startability is poor ....5348
S-5 Engine does not pick-up smoothly ....5350
S-6 Engine stops during operation ....5352
S-7 Engine runs rough or is unstable ....5354
S-8 Engine lacks power ....5355
S-9 KDPF gets clogged in a short time ....5357
S-10 Engine oil consumption is excessive ....5359
S-11 Engine oil becomes contaminated early ....5360
S-12 Fuel consumption is excessive ....5361
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ....5362
S-14 Oil pressure drops ....5363
S-15 Fuel mixes into engine oil ....5364
S-16 Water mixes into engine oil (milky) ....5365
S-17 Coolant temperature rises too high (overheating) ....5366
S-18 Unusual noise is heard ....5367
S-19 Vibration is excessive ....5368
S-20 Air cannot be bled from fuel circuit ....5369
S-21 Active regeneration is executed frequently ....5370
S-22 Active regeneration takes a long time ....5371
S-23 White smoke is exhausted during active regeneration ....5372
50 Disassembly and assembly ....5374
Table of contents ....5375
General information on disassembly and assembly ....5377
How to read this manual ....5377
Coating materials list ....5379
Special tools list ....5383
Sketches of special tools ....5390
Engine and cooling system ....5420
Removal and installation of supply pump assembly ....5420
Removal and installation of injector assembly ....5426
Removal and installation of fuel doser assembly ....5434
Removal and installation of cylinder head assembly ....5436
Removal and installation of engine hood assembly ....5450
Removal and installation of grille assembly ....5452
Removal and installation of cooling system assembly ....5455
Removal and installation of radiator core assembly ....5458
Removal and installation of aftercooler ....5460
Removal and installation of hydraulic oil cooler ....5463
Removal and installation of power train oil cooler assembly ....5465
Removal and installation of engine assembly ....5469
Removal and installation of engine front oil seal ....5475
Removal and installation of engine rear oil seal ....5478
Removal and installation of cooling fan and cooling fan motor assembly ....5483
Removal and installation of KDPF assembly ....5485
Disassembly and assembly of KDPF assembly ....5490
Removal and installation of KCCV assembly ....5499
Removal and installation of KVGT assembly ....5501
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ....5506
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ....5507
Removal and installation of air cleaner assembly ....5509
Removal and installation of air conditioner compressor belt ....5511
Removal and installation of alternator belt ....5512
Removal and installation of fuel tank assembly ....5513
Power train ....5516
Removal and installation of torque converter and transmission assembly ....5516
Disassembly and assembly of transmission assembly ....5521
Disassembly and assembly of torque converter assembly ....5551
Disassembly and assembly of transmission clutch pack assembly ....5558
Removal and installation of front axle assembly ....5581
Removal and installation of rear axle assembly ....5583
Disassembly and assembly of axle housing assembly ....5588
Disassembly and assembly of differential assembly ....5598
Steering system ....5617
Removal and installation of steering valve assembly ....5617
Brake system ....5619
Removal and installation of brake charge valve assembly ....5619
Removal and installation of parking brake disc and plate ....5620
Undercarriage and frame ....5623
Removal and installation of center hinge pin ....5623
Removal and installation of counterweight assembly ....5631
Removal and installation of full-length fender assembly ....5633
Hydraulic system ....5634
Removal and installation of hydraulic tank assembly ....5634
Removal and installation of control valve assembly ....5637
Removal and installation of steering pump and power train pump assembly ....5640
Removal and installation of work equipment pump and cooling fan pump assembly ....5642
Disassembly and assembly of hydraulic cylinder assembly ....5644
Work equipment ....5651
Removal and installation of work equipment assembly ....5651
Cab and its attachments ....5656
Removal and installation of operator's cab and floor frame assembly ....5656
Removal and installation of operator's cab glass (stuck window glass) ....5660
Removal and installation of operator's seat assembly ....5668
Removal and installation of seat belt ....5670
Removal and installation of air conditioner unit assembly ....5671
Removal and installation of air conditioner compressor assembly ....5676
Removal and installation of air conditioner condenser assembly ....5678
Electrical system ....5680
Removal and installation of machine monitor assembly ....5680
Removal and installation of engine controller assembly ....5681
Removal and installation of work equipment controller assembly ....5682
Removal and installation of transmission controller assembly ....5684
Removal and installation of monitor controller assembly ....5685
Removal and installation of mass air flow and temperature sensor ....5687
Removal and installation of KOMTRAX terminal assembly ....5688
60 Maintenance standard ....5690
Table of contents ....5691
Engine and cooling system ....5692
Engine related parts ....5692
Cooling fan pump ....5693
Cooling fan motor ....5696
Power train ....5698
Drive shaft ....5698
Torque converter ....5699
Transmission ....5701
Transmission control valve ....5710
Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV ....5712
3rd, 4th clutch ECMV ....5713
Lockup clutch ECMV ....5714
Main relief and torque converter relief valve ....5715
Axle ....5716
Differential ....5718
Final drive ....5728
Steering system ....5730
Steering column ....5730
Steering pump ....5731
Steering valve ....5735
Steering cylinder ....5737
Emergency steering pump ....5740
Brake system ....5741
Charge valve ....5741
Slack adjuster ....5743
Brake ....5744
Parking brake ....5746
Parking brake solenoid valve ....5747
Undercarriage and frame ....5748
Axle mount and center hinge pin ....5748
Hydraulic system ....5752
Hydraulic tank ....5752
Double type gear pump ....5753
Work equipment pump ....5754
Control valve ....5756
Work equipment ....5765
Work equipment linkage ....5765
Bucket ....5769
Work equipment cylinder ....5770
80 Appendix ....5772
Table of contents ....5773
Air conditioner components ....5774
Precautions for refrigerant ....5774
Air conditioner component ....5775
Configuration and function of refrigeration cycle ....5777
Outline of refrigeration cycle ....5778
Air conditioner unit ....5780
Dual pressure switch ....5785
Air conditioner controller ....5786
Compressor ....5787
Condenser ....5788
Receiver drier ....5789
Sunlight sensor ....5791
Outer temperature sensor (outside air temperature sensor) ....5792
Procedure for testing and troubleshooting ....5793
Circuit diagram and arrangement of connector pins ....5795
System diagram ....5798
Parts and connectors layout ....5801
Testing with self-diagnosis function ....5806
How to open the electrical system abnormality record screen in service mode of the machine monitor ....5807
Testing temperature control system ....5809
Testing vent (mode) changeover ....5811
Testing FRESH/RECIRC air changeover ....5813
Check evaporator temperature sensor ....5815
Testing relays ....5817
Troubleshooting chart 1 ....5819
Troubleshooting chart 2 ....5820
Information in troubleshooting table ....5822
Failure code list related to air conditioner ....5823
Failure code [879AKA] A/C Inner Sensor Open Circuit ....5824
Failure code [879AKB] A/C Inner Sensor Short Circuit ....5826
Failure code [879BKA] A/C Outer Sensor Open Circuit ....5828
Failure code [879BKB] A/C Outer Sensor Short Circuit ....5830
Failure code [879CKA] Ventilating Sensor Open Circuit ....5832
Failure code [879CKB] Ventilating Sensor Short Circuit ....5834
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ....5836
Failure code [879EMC] Ventilation Damper Abnormality ....5838
Failure code [879FMC] Air Mix Damper Abnormality ....5841
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) ....5844
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ....5847
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ....5850
A-4 Troubleshooting for FRESH/RECIRC air changeover ....5853
Troubleshooting with gauge pressure ....5855
Connection of service tool ....5858
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ....5860
Handling of compressor oil ....5862
90 Diagrams and drawings ....5864
Table of contents ....5865
Hydraulic circuit diagram ....5866
Symbols in hydraulic circuit diagram ....5866
Hydraulic circuit diagram of power train ....5870
Electric circuit diagram ....5873
Symbols in electric circuit diagram ....5873
Blank Page....3557
CEBM030000 - Wheel Loader WA470-8 Shop Manual....5904
CEBM030000 WA470-8 S/N A49001 AND UP....5904
00 INDEX AND FOREWORD....5906
INDEX....5907
FOREWORD, SAFETY, BASIC INFORMATION....5926
HOW TO READ THE SHOP MANUAL....5926
SAFETY NOTICE FOR OPERATION....5928
PRECAUTIONS TO PREVENT FIRE....5936
ACTION IF FIRE OCCURS....5938
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS....5939
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS....5940
PRECAUTIONS FOR DEF....5941
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING....5941
PRECAUTIONS FOR ADDING....5941
PRECAUTIONS FOR STORING....5941
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE....5941
THE OTHER PRECAUTIONS....5941
STORE AdBlue/DEF....5942
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT....5943
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS....5945
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT....5951
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT....5953
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT....5954
PRACTICAL USE OF KOMTRAX....5955
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER....5956
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER....5956
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER....5957
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER....5958
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS....5960
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR....5964
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR....5965
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL....5967
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH....5968
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE....5970
HOW TO READ ELECTRICAL WIRE CODE....5971
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD....5975
ABBREVIATION LIST....5978
STANDARD TIGHTENING TORQUE TABLE....5984
CONVERSION TABLE....5991
01 SPECIFICATIONS....5996
CONTENTS....5997
SPECIFICATIONS....5998
SPECIFICATION DRAWING....5998
SPECIFICATION DRAWING: WA470-8....5998
SPECIFICATIONS....6000
SPECIFICATIONS: WA470-8....6000
WEIGHT TABLE....6005
WEIGHT TABLE:WA470-8....6005
TABLE OF FUEL, COOLANT, AND LUBRICANTS....6007
10 STRUCTURE AND FUNCTION....6010
CONTENTS....6011
UREA SCR SYSTEM....6015
LAYOUT DRAWING OF UREA SCR SYSTEM....6015
UREA SCR SYSTEM DIAGRAM....6019
FUNCTION OF UREA SCR SYSTEM....6020
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM....6020
INDUCEMENT STRATEGY....6022
COMPONENT PARTS OF UREA SCR SYSTEM....6034
AdBlue/DEF MIXING TUBE....6034
SCR ASSEMBLY....6034
AdBlue/DEF TANK....6037
AdBlue/DEF PUMP....6039
AdBlue/DEF INJECTOR....6040
AdBlue/DEF HOSE....6041
AdBlue/DEF TANK HEATING VALVE....6042
BOOT-UP SYSTEM....6043
LAYOUT DRAWING OF BOOT-UP SYSTEM....6043
SYSTEM OPERATING LAMP SYSTEM....6045
SYSTEM OPERATING LAMP SYSTEM DIAGRAM....6045
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM....6045
BATTERY DISCONNECT SWITCH....6046
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH....6046
FUNCTION OF BATTERY DISCONNECT SWITCH....6046
PREHEATING SYSTEM....6048
PREHEATING SYSTEM DIAGRAM....6048
FUNCTION OF AUTOMATIC PREHEATING SYSTEM....6048
OPERATION OF AUTOMATIC PREHEATING SYSTEM....6048
FUNCTION OF MANUAL PREHEATING SYSTEM....6049
OPERATION OF MANUAL PREHEATING SYSTEM....6049
ENGINE SYSTEM....6050
LAYOUT DRAWING OF ENGINE RELATED PARTS....6050
FUNCTIONS OF ENGINE RELATED PARTS....6052
ENGINE CONTROL SYSTEM....6053
ENGINE CONTROL SYSTEM DIAGRAM....6053
FUNCTION OF ENGINE CONTROL SYSTEM....6054
OPERATION OF ENGINE CONTROL SYSTEM....6056
ENGINE POWER MODE SELECTOR SYSTEM....6058
ENGINE POWER MODE SELECTOR SYSTEM DIAGRAM....6058
FUNCTION OF ENGINE POWER MODE SELECTOR SYSTEM....6058
OPERATION OF ENGINE POWER MODE SELECTOR SYSTEM....6058
AUTOMATIC IDLE STOP SYSTEM....6059
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM....6059
COMPONENT PARTS OF ENGINE SYSTEM....6060
KVGT....6060
EGR SYSTEM....6063
EGR VALVE....6065
EGR COOLER....6067
KCCV SYSTEM....6068
KCCV VENTILATOR....6069
KDPF....6071
COOLING SYSTEM....6076
LAYOUT DRAWING OF COOLING SYSTEM....6076
SPECIFICATIONS OF COOLING SYSTEM....6077
COOLING FAN CONTROL SYSTEM....6079
COOLING FAN CONTROL SYSTEM DIAGRAM....6079
FUNCTION OF COOLING FAN CONTROL SYSTEM....6079
COMPONENT PARTS OF COOLING SYSTEM....6084
BRAKE AND COOLING FAN PUMP....6084
COOLING FAN MOTOR....6091
CONTROL SYSTEM....6097
LAYOUT DRAWING OF CONTROL SYSTEM PARTS....6097
MACHINE MONITOR SYSTEM....6099
MACHINE MONITOR SYSTEM DIAGRAM....6099
FUNCTION OF MACHINE MONITOR SYSTEM....6099
REARVIEW MONITOR SYSTEM....6101
REARVIEW MONITOR SYSTEM DIAGRAM....6101
FUNCTION OF REARVIEW MONITOR SYSTEM....6101
KOMTRAX SYSTEM....6102
KOMTRAX SYSTEM DIAGRAM....6102
FUNCTION OF KOMTRAX SYSTEM....6102
COMPONENT PARTS OF CONTROL SYSTEM....6103
MACHINE MONITOR....6103
SWITCH PANEL....6124
REARVIEW MONITOR....6125
REARVIEW CAMERA....6126
KOMTRAX TERMINAL....6127
TRANSMISSION CONTROLLER....6129
WORK EQUIPMENT CONTROLLER....6133
MONITOR CONTROLLER....6137
CAN TERMINATING RESISTOR....6145
ENGINE CONTROLLER....6147
ACCELERATOR PEDAL....6153
HYDRAULIC SYSTEM....6155
LAYOUT DRAWING OF HYDRAULIC SYSTEM....6155
CLSS....6156
STRUCTURE OF CLSS....6156
FUNCTION OF CLSS....6157
WORK EQUIPMENT PUMP AND STEERING PUMP CONTROL SYSTEM....6159
SWASH PLATE CONTROL FUNCTION OF WORK EQUIPMENT PUMP AND STEERING PUMP....6159
PICKUP ASSISTANCE CONTROL FUNCTION WHEN ENGINE SPEED IS LOW....6159
OVERHEAT PREVENTION FUNCTION OF WORK EQUIPMENT CIRCUIT....6159
COMPONENT PARTS OF HYDRAULIC SYSTEM....6160
HYDRAULIC TANK....6160
WORK EQUIPMENT PUMP....6163
STEERING PUMP....6181
POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP....6192
CONTROL VALVE....6193
POWER TRAIN SYSTEM....6227
LAYOUT DRAWING OF POWER TRAIN SYSTEM....6227
OPERATION OF POWER TRAIN SYSTEM....6230
TRANSMISSION CONTROL SYSTEM....6231
TRANSMISSION CONTROL SYSTEM DIAGRAM....6231
TRANSMISSION GEAR SHIFT CONTROL SYSTEM....6233
ELECTRIC MODULATION FUNCTION SYSTEM DIAGRAM....6233
ELECTRIC MODULATION FUNCTION....6234
DISPLAY FUNCTION OF GEAR SHIFT....6234
AUTOMATIC GEAR SHIFT FUNCTION....6234
SHIFT HOLD FUNCTION....6235
KICKDOWN FUNCTION....6235
AUTOMATIC KICKDOWN FUNCTION....6236
TORQUE CONVERTER LOCKUP FUNCTION....6236
HUNTING PREVENTION FUNCTION....6237
ADJUSTING FUNCTION OF TRANSMISSION INITIAL LEARNING AND ECMV CURRENT....6237
SHIFT POINT CHANGING FUNCTION....6237
4TH GEAR SPEED LIMITATION FUNCTION....6238
TRANSMISSION PROTECTION FUNCTION....6239
PROTECTION FUNCTION WHEN TRAVEL DIRECTION IS CHANGED....6239
SHIFT DOWN PROTECTION FUNCTION....6239
ENGINE OVERRUN PREVENTION FUNCTION....6240
MAXIMUM SPEED LIMITATION FUNCTION....6240
NEUTRALIZER FUNCTION....6240
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION....6242
TRANSMISSION CUT-OFF FUNCTION....6244
COMPONENT PARTS OF POWER TRAIN SYSTEM....6246
DRIVE SHAFT....6246
TORQUE CONVERTER....6248
LOCKUP CLUTCH ECMV....6250
TRANSMISSION....6254
TRANSMISSION CONTROL VALVE....6267
FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND CLUTCH ECMV....6269
3RD AND 4TH CLUTCH ECMV....6274
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE....6280
AXLE....6282
CONVENTIONAL DIFFERENTIAL....6284
LIMITED SLIP DIFFERENTIAL....6286
FINAL DRIVE....6291
COMBINATION SWITCH....6293
SHIFT HOLD SWITCH....6296
KICKDOWN SWITCH....6297
WORK EQUIPMENT SYSTEM....6298
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM....6298
WORK EQUIPMENT SYSTEM DIAGRAM....6300
WORK EQUIPMENT CONTROL SYSTEM....6302
WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE....6302
WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION....6302
WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM....6303
WORK EQUIPMENT LEVER OPERATION FUNCTION....6304
BUCKET PRIORITY CONTROL FUNCTION....6304
BOOM STOP MODULATION FUNCTION....6304
WORK EQUIPMENT NEUTRAL LOCK SYSTEM....6306
WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM....6306
FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM....6306
REMOTE POSITIONER SYSTEM....6308
REMOTE BUCKET POSITIONER SYSTEM DIAGRAM....6308
FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM....6308
REMOTE BOOM POSITIONER SYSTEM DIAGRAM....6309
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM....6309
BUCKET POSITIONER AND BOOM POSITIONER....6313
STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER....6313
SEMI AUTO-DIGGING SYSTEM....6314
SEMI AUTO-DIGGING SYSTEM DIAGRAM....6314
FUNCTION OF SEMI AUTO-DIGGING SYSTEM....6314
ECSS....6316
ECSS DIAGRAM....6316
FUNCTION OF ECSS....6316
OPERATION OF ECSS....6316
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM....6318
WORK EQUIPMENT LOCK SOLENOID VALVE....6318
PILOT CIRCUIT ACCUMULATOR....6319
ECSS CIRCUIT ACCUMULATOR....6320
WORK EQUIPMENT ELECTRIC LEVER....6321
MULTIFUNCTION MONO-LEVER....6324
STEERING SYSTEM....6325
LAYOUT DRAWING OF STEERING SYSTEM....6325
SECONDARY STEERING SYSTEM....6326
SECONDARY STEERING SYSTEM DIAGRAM....6326
FUNCTION OF SECONDARY STEERING SYSTEM....6326
JOYSTICK STEERING SYSTEM....6328
FUNCTION OF JOYSTICK STEERING SYSTEM....6328
JOYSTICK CONTROL FUNCTION....6328
JOYSTICK NEUTRAL SAFETY FUNCTION....6331
JOYSTICK NEUTRAL INTERLOCK FUNCTION....6331
JOYSTICK SPEED SENSING STEERING FUNCTION....6331
JOYSTICK Hi/Lo SELECTOR FUNCTION....6332
STEERING COLUMN....6333
STRUCTURE OF STEERING COLUMN....6333
COMPONENT PARTS OF STEERING SYSTEM....6334
STEERING VALVE....6334
ORBITROL VALVE....6347
STOP VALVE....6351
SECONDARY STEERING PUMP....6352
SECONDARY STEERING MOTOR....6353
JOYSTICK KNOB....6354
BRAKE SYSTEM....6355
LAYOUT DRAWING OF BRAKE SYSTEM....6355
PARKING BRAKE CONTROL SYSTEM....6357
PARKING BRAKE CONTROL SYSTEM DIAGRAM....6357
OPERATION OF PARKING BRAKE CONTROL SYSTEM....6357
COMPONENT PARTS OF BRAKE SYSTEM....6359
CHARGE VALVE....6359
PARKING BRAKE SOLENOID VALVE....6364
SECONDARY PARKING BRAKE RELEASE VALVE....6366
BRAKE CIRCUIT ACCUMULATOR....6367
BRAKE VALVE....6368
SLACK ADJUSTER....6372
BRAKE....6374
PARKING BRAKE....6377
UNDERCARRIAGE AND FRAME....6379
FRAME, AXLE MOUNT AND CENTER HINGE PIN....6379
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN....6379
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN....6380
TIRE....6381
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE....6381
STRUCTURE OF RADIAL TIRE....6381
FUNCTION OF RADIAL TIRE....6381
STRUCTURE OF BIAS TIRE....6382
FUNCTION OF BIAS TIRE....6382
WORK EQUIPMENT....6383
STRUCTURE OF WORK EQUIPMENT....6383
STRUCTURE OF BUCKET....6384
CAB AND ITS ATTACHMENTS....6385
ROPS CAB....6385
STRUCTURE OF ROPS CAB....6385
FUNCTION OF ROPS CAB....6385
20 STANDARD VALUE TABLE....6386
CONTENTS....6387
STANDARD VALUE TABLE FOR ENGINE....6388
STANDARD VALUE TABLE FOR ENGINE: WA470-8....6388
STANDARD VALUE TABLE FOR MACHINE....6392
STANDARD VALUE TABLE FOR MACHINE: WA470-8....6392
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE....6410
STANDARD VALUE TABLE FOR ELECTRICAL....6414
STANDARD VALUE TABLE FOR ELECTRICITY....6414
30 TESTING AND ADJUSTING....6434
CONTENTS....6435
RELATED INFORMATION ON TESTING AND ADJUSTING....6439
TOOLS FOR TESTING AND ADJUSTING....6439
SKETCH OF TOOLS FOR TESTING AND ADJUSTING....6448
ENGINE AND COOLING SYSTEM....6450
TEST ENGINE SPEED....6450
METHOD FOR TESTING ENGINE SPEED....6450
TEST BOOST PRESSURE....6455
METHOD FOR TESTING BOOST PRESSURE....6455
TESTING EXHAUST GAS TEMPERATURE....6458
METHOD FOR TESTING EXHAUST GAS TEMPERATURE....6458
TEST EXHAUST GAS COLOR....6460
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER....6460
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER....6461
TEST AND ADJUST VALVE CLEARANCE....6463
METHOD FOR TESTING VALVE CLEARANCE....6463
METHOD FOR ADJUSTING VALVE CLEARANCE....6465
TEST COMPRESSION PRESSURE....6466
METHOD FOR TESTING COMPRESSION PRESSURE....6466
TEST BLOWBY PRESSURE....6470
METHOD FOR TESTING BLOWBY PRESSURE....6470
TEST ENGINE OIL PRESSURE....6473
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR....6473
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL....6473
TEST EGR VALVE AND KVGT OIL PRESSURE....6475
METHOD FOR TESTING EGR VALVE AND KVGT OIL PRESSURE....6475
TEST FUEL PRESSURE....6477
METHOD FOR TESTING FUEL PRESSURE....6477
TEST FUEL RETURN RATE AND LEAKAGE....6479
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE....6480
BLEEDING AIR FROM FUEL SYSTEM....6483
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM....6484
TEST FUEL CIRCUIT FOR LEAKAGE....6485
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE....6485
HANDLE CYLINDER CUT-OUT MODE OPERATION....6487
HANDLE NO-INJECTION CRANKING OPERATION....6488
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE....6489
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE....6489
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS....6490
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS....6490
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS....6491
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS....6491
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION....6492
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION....6492
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION....6492
CLEAN FUEL DOSER....6494
METHOD FOR CLEANING FUEL DOSER....6494
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER....6496
METHOD FOR WRITING INJECTOR COMPENSATION VALUE....6496
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER....6503
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER....6503
TEST SCR RELATED FUNCTIONS....6504
TEST AdBlue/DEF PUMP RAISED PRESSURE....6507
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR....6509
TEST AdBlue/DEF LINE HEATER RELAY 1....6513
TEST AdBlue/DEF LINE HEATER RELAY 2....6516
TEST AdBlue/DEF PUMP HEATER RELAY....6519
TEST AdBlue/DEF TANK HEATER VALVE....6523
TEST SCR NOx REMOVAL EFFICIENCY....6526
CLEAN AdBlue/DEF TANK....6530
METHOD FOR CLEANING AdBlue/DEF TANK....6530
POWER TRAIN....6534
TEST AND ADJUST POWER TRAIN OIL PRESSURE....6534
METHOD FOR TESTING POWER TRAIN OIL PRESSURE....6537
METHOD FOR ADJUSTING POWER TRAIN OIL PRESSURE....6552
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR....6553
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR....6553
ADJUST TRANSMISSION INPUT SPEED SENSOR....6554
METHOD FOR ADJUSTING TRANSMISSION INPUT SPEED SENSOR....6554
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT....6555
METHOD FOR FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT....6555
MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE....6557
METHOD FOR MOVING DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE....6558
TEST OIL LEAKAGE FROM AXLE FINAL DRIVE....6560
METHOD FOR TESTING OIL LEAKAGE FROM AXLE FINAL DRIVE....6560
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE....6561
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE....6561
STEERING SYSTEM....6562
TEST STEERING WHEEL....6562
METHOD FOR TESTING STEERING WHEEL....6562
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE....6564
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE....6564
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE....6567
BLEED AIR FROM STEERING CYLINDER CIRCUIT....6568
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT....6568
TEST AND ADJUST STEERING STOP VALVE....6570
METHOD FOR TESTING STEERING STOP VALVE....6570
METHOD FOR ADJUSTING STEERING STOP VALVE....6570
BRAKE SYSTEM....6571
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT....6571
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT....6571
TEST WHEEL BRAKE OIL PRESSURE....6572
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE....6572
TEST AND ADJUST ACCUMULATOR CHARGE PRESSURE....6575
METHOD FOR TESTING ACCUMULATOR CHARGE PRESSURE....6575
METHOD FOR ADJUSTING ACCUMULATOR CHARGE PRESSURE....6576
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE....6577
METHOD FOR TESTING ACCUMULATOR NITROGEN GAS PRESSURE....6577
METHOD FOR CHARGING ACCUMULATOR NITROGEN GAS PRESSURE....6579
TEST BRAKING PERFORMANCE....6582
METHOD FOR TESTING BRAKING PERFORMANCE....6582
TEST BRAKE PEDAL....6583
METHOD FOR TESTING BRAKE PEDAL....6583
BLEED AIR FROM BRAKE CIRCUIT....6584
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT....6584
TEST AND ADJUST BRAKE PEDAL AND LINKAGE....6587
METHOD FOR TESTING BRAKE PEDAL AND LINKAGE....6587
METHOD FOR ADJUSTING BRAKE PEDAL AND LINKAGE....6587
TEST LOWERING OF WHEEL BRAKE PRESSURE....6588
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE....6589
TEST WEAR OF WHEEL BRAKE DISC....6591
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC....6591
TEST PARKING BRAKE OIL PRESSURE....6593
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE....6593
TEST PARKING BRAKE PERFORMANCE....6595
METHOD FOR TESTING PARKING BRAKE PERFORMANCE....6595
RELEASE PARKING BRAKE MANUALLY....6596
METHOD FOR RELEASING PARKING BRAKE MANUALLY....6596
TEST WEAR AMOUNT OF PARKING BRAKE DISC....6598
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC....6598
HYDRAULIC SYSTEM....6600
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT....6600
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT....6600
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE....6602
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE....6602
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE....6607
TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE....6608
METHOD FOR TESTING WORK EQUIPMENT EPC OIL PRESSURE....6608
METHOD FOR ADJUSTING WORK EQUIPMENT EPC OIL PRESSURE....6611
BLEED AIR FROM WORK EQUIPMENT CIRCUIT....6613
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT....6613
TEST COOLING FAN SPEED....6614
METHOD FOR TESTING COOLING FAN SPEED....6614
TEST COOLING FAN CIRCUIT OIL PRESSURE....6616
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE....6616
BLEED AIR FROM HYDRAULIC FAN CIRCUIT....6619
METHOD FOR BLEEDING AIR FROM HYDRAULIC FAN CIRCUIT....6619
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS....6621
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE....6621
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS....6623
WORK EQUIPMENT....6627
TEST AND ADJUST BUCKET POSITIONER DETECTION LEVER....6627
METHOD FOR TESTING BUCKET POSITIONER DETECTION LEVER....6627
METHOD FOR ADJUSTING BUCKET POSITIONER DETECTION LEVER....6627
TEST AND ADJUST BOOM POSITION DETECTION LEVER....6629
METHOD FOR TESTING BOOM POSITION DETECTION LEVER....6629
METHOD FOR ADJUSTING BOOM POSITION DETECTION LEVER....6629
CAB AND ITS ATTACHMENTS....6630
TEST DIRECTIONAL LEVER....6630
METHOD FOR TESTING DIRECTIONAL LEVER....6630
TEST WORK EQUIPMENT CONTROL LEVER....6631
METHOD FOR TESTING WORK EQUIPMENT CONTROL LEVER....6631
ELECTRICAL SYSTEM....6634
SET AND ADJUST EACH EQUIPMENT....6634
PREPARATION FOR TRANSMISSION ECMV CURRENT ADJUSTMENT....6636
METHOD FOR ADJUSTING TRANSMISSION ECMV CURRENT....6638
METHOD FOR SETTING AND RESETTING TRANSMISSION INITIAL LEARNING....6641
SET AND OPERATE MACHINE MONITOR....6646
OPERATOR MODE....6649
SERVICE MODE....6655
METHOD FOR STARTING UP KOMTRAX TERMINAL....6759
ADJUST REARVIEW CAMERA ANGLE....6764
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE....6764
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER....6766
HANDLE BATTERY DISCONNECT SWITCH....6767
TEST DIODES....6768
METHOD FOR TESTING DIODE USING DIGITAL TESTER....6768
METHOD FOR TESTING DIODE USING ANALOG TESTER....6768
Pm CLINIC....6769
Pm CLINIC SERVICE....6769
Pm CLINIC CHECK SHEET....6771
40 TROUBLESHOOTING....6782
CONTENTS....6783
RELATED INFORMATION ON TROUBLESHOOTING....6795
GENERAL TROUBLESHOOTING POINTS....6795
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM....6796
SEQUENCE OF EVENTS IN TROUBLESHOOTING....6808
CHECKS BEFORE TROUBLESHOOTING....6810
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING....6812
WALK-AROUND CHECK....6812
TESTING IN ACCORDANCE WITH TESTING PROCEDURE....6814
FUEL - CHECK LEVEL AND TYPE....6814
FUEL - CHECK FOR FOREIGN MATERIAL....6814
CHECK AdBule/DEF LEVEL AND TYPE....6815
FUEL PREFILTER - CHECK....6815
MAIN FILTER - CHECK....6817
OIL PAN - CHECK ENGINE OIL LEVEL AND TYPE....6818
RESERVOIR TANK - CHECK COOLANT LEVEL....6818
AIR CLEANER - CHECK FOR CLOGGING....6819
OUTER ELEMENT - CLEAN....6820
REPLACE ELEMENT....6822
HYDRAULIC OIL - CHECK OIL LEVEL....6823
HYDRAULIC OIL STRAINER - CHECK....6824
HYDRAULIC OIL FILTER - CHECK....6825
CHECK OIL LEVEL IN TRANSMISSION CASE....6826
CHECK OIL LEVEL IN FRONT AXLE CASE....6828
CHECK OIL LEVEL IN REAR AXLE CASE....6829
FUEL SYSTEM - BLEED AIR....6829
HYDRAULIC CIRCUIT - BLEED AIR....6829
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod....6829
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION....6835
PROCEDURE FOR TESTING AND TROUBLESHOOTING....6847
SYMPTOM AND TROUBLESHOOTING NUMBERS....6849
INFORMATION IN TROUBLESHOOTING TABLE....6854
CONNECTORS LIST AND LAYOUT....6856
CONNECTOR PIN NUMBERS - CONNECTION TABLE....6875
T-BOXES AND T-ADAPTERS LIST....6915
FUSE LOCATION TABLE....6921
PRECAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE....6924
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR....6928
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT....6930
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])....6936
FAILURE CODES TABLE....6938
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)....6961
FAILURE CODE [1500L0] T/M Clutches Double Engagement....6961
FAILURE CODE [15SAL1] ECMV Release Trouble (Forward)....6962
FAILURE CODE [15SALH] ECMV Engage Trouble (Forward)....6964
FAILURE CODE [15SBL1] ECMV Release Trouble (Reverse Clutch)....6966
FAILURE CODE [15SBLH] ECMV Engage Trouble (Reverse)....6968
FAILURE CODE [15SEL1] ECMV Release Trouble (1st Clutch)....6970
FAILURE CODE [15SELH] ECMV Engage Trouble (1st)....6972
FAILURE CODE [15SFL1] ECMV Release Trouble (2nd Clutch)....6974
FAILURE CODE [15SFLH] ECMV Engage Trouble (2nd)....6976
FAILURE CODE [15SGL1] ECMV Release Trouble (3rd Clutch)....6978
FAILURE CODE [15SGLH] ECMV Engage Trouble (3rd)....6980
FAILURE CODE [15SHL1] ECMV Release Trouble (4th)....6982
FAILURE CODE [15SHLH] ECMV Engage Trouble (4th)....6984
FAILURE CODE [2F00MA] Parking Brake Defective Function....6987
FAILURE CODE [2F00MB] Malfunction of Parking Brake....6991
FAILURE CODE [2G42ZG] Accumulator Oil Pressure Low (Front)....6994
FAILURE CODE [2G43ZG] Accumulator Oil Pressure Low (Rear)....6996
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit....6998
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit....7000
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit....7002
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit....7004
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit....7006
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit....7008
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit....7010
FAILURE CODE [879EMC] Ventilation Damper Malfunction....7012
FAILURE CODE [879FMC] Air Mix Damper Malfunction....7015
FAILURE CODE [989A00] Engine Overrun....7018
FAILURE CODE [989L00] Engine Controller Lock Caution 1....7019
FAILURE CODE [989M00] Engine Controller Lock Caution 2....7020
FAILURE CODE [989N00] Engine Controller Lock Caution 3....7021
FAILURE CODE [A1U0N3] HC Desorb Request 1....7022
FAILURE CODE [A1U0N4] HC Desorb Request 2....7024
FAILURE CODE [AA10NX] Air Cleaner Clogging....7026
FAILURE CODE [AB00KE] Charge Voltage Low....7028
FAILURE CODE [AB00KY] Hot Short of Alternator R Terminal....7030
FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging)....7032
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR)....7034
FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality)....7036
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality)....7037
FAILURE CODE [AS00R4] Inducement 2 (SCR Device Abnormality)....7038
FAILURE CODE [AS00R5] Inducement 3 (SCR Device Abnormality)....7039
FAILURE CODE [AS00R6] Temporary Recovery of Inducement....7040
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5....7041
FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning....7042
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning....7043
FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution....7044
FAILURE CODE [B@BAZG] Eng Oil Press Low....7045
FAILURE CODE [B@BAZK] Eng Oil Level Low....7046
FAILURE CODE [B@BCNS] Eng Water Overheat....7048
FAILURE CODE [B@BCZK] Engine Coolant Level Low....7049
FAILURE CODE [B@CENS] Power Train Oil Overheat....7051
FAILURE CODE [B@HANS] Hydraulic Oil Overheat....7052
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error....7053
FAILURE CODE [CA122] Charge Air Pressure Sensor High Error....7054
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error....7056
FAILURE CODE [CA131] Throttle Sensor High Error....7058
FAILURE CODE [CA132] Throttle Sensor Low Error....7060
FAILURE CODE [CA135] Engine Oil Pressure Sensor High Error....7063
FAILURE CODE [CA141] Engine Oil Pressure Sensor Low Error....7065
FAILURE CODE [CA144] Coolant Temperature Sensor High Error....7067
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error....7069
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error....7071
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error....7074
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error....7077
FAILURE CODE [CA221] Ambient Pressure Sensor High Error....7079
FAILURE CODE [CA222] Ambient Pressure Sensor Low Error....7081
FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error....7083
FAILURE CODE [CA234] Engine Overspeed....7084
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error....7085
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error....7087
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error....7089
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error....7091
FAILURE CODE [CA271] IMV or PCV 1 Short Circuit Error....7093
FAILURE CODE [CA272] IMV or PCV 1 Open Circuit Error....7095
FAILURE CODE [CA273] PCV 2 Short Circuit Error....7096
FAILURE CODE [CA274] PCV 2 Open Circuit Error....7098
FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Circuit Error....7099
FAILURE CODE [CA323] Injector #5 (L#5) Open Circuit Error or Short Circuit Error....7101
FAILURE CODE [CA324] Injector #3 (L#3) Open Circuit Error or Short Circuit Error....7103
FAILURE CODE [CA325] Injector #6 (L#6) Open Circuit Error or Short Circuit Error....7105
FAILURE CODE [CA331] Injector #2 (L#2) Open Circuit Error or Short Circuit Error....7107
FAILURE CODE [CA332] Injector #4 (L#4) Open Circuit Error or Short Circuit Error....7109
FAILURE CODE [CA343] Engine Controller Internal Failure....7111
FAILURE CODE [CA351] Injectors Drive Circuit Error....7112
FAILURE CODE [CA352] Sensor 1 Supply Voltage Low Error....7113
FAILURE CODE [CA356] MAF Sensor High Error....7116
FAILURE CODE [CA357] MAF Sensor Low Error....7118
FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error....7120
FAILURE CODE [CA431] Idle Validation Sw Error....7121
FAILURE CODE [CA432] Idle Validation Process Error....7124
FAILURE CODE [CA441] Battery Voltage Low Error....7128
FAILURE CODE [CA442] Battery Voltage High Error....7130
FAILURE CODE [CA449] Common Rail Pressure High Error 2....7131
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error....7132
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error....7134
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error....7136
FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage Low Error....7138
FAILURE CODE [CA553] Common Rail Pressure High Error 1....7140
FAILURE CODE [CA555] Crankcase Pressure High Error 1....7141
FAILURE CODE [CA556] Crankcase Pressure High Error 2....7142
FAILURE CODE [CA559] Common Rail Pressure Low Error 1....7143
FAILURE CODE [CA595] Turbocharger Speed High Error 2....7148
FAILURE CODE [CA687] Turbocharger Speed Low Error....7149
FAILURE CODE [CA689] Engine NE Speed Sensor Error....7151
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error....7153
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error....7155
FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor High Error....7157
FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor Low Error....7158
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error....7159
FAILURE CODE [CA778] Engine Backup Speed Sensor Error....7160
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error....7163
FAILURE CODE [CA1664] KDOC Abnormality....7164
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error....7167
FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3....7168
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error....7169
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error....7170
FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error....7171
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error....7173
FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error....7175
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error....7177
FAILURE CODE [CA1691] Defective Regeneration....7178
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error....7181
FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error....7184
FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error....7185
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error....7187
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error....7190
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error....7192
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error....7193
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error....7194
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error....7197
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error....7200
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error....7202
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error....7205
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error....7208
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Error....7210
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error....7214
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error....7216
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1....7218
FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 2....7221
FAILURE CODE [CA1923] Fuel Doser Solenoid 1 High Error....7226
FAILURE CODE [CA1924] Fuel Doser Solenoid 1 Low Error....7228
FAILURE CODE [CA1925] Fuel Doser Solenoid 1 In Range Error....7230
FAILURE CODE [CA1927] Dosing Fuel Pressure Sensor High Error....7232
FAILURE CODE [CA1928] Dosing Fuel Pressure Sensor Low Error....7234
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error....7236
FAILURE CODE [CA1963] Fuel Doser Solenoid 1 Servo Error....7237
FAILURE CODE [CA1977] Fuel Doser Open Error or Short Error....7240
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error....7243
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error....7246
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error....7248
FAILURE CODE [CA2249] Common Rail Pressure Low Error 2....7250
FAILURE CODE [CA2265] Fuel Feed Pump Open Circuit Error....7251
FAILURE CODE [CA2266] Fuel Feed Pump Short Circuit Error....7253
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error....7256
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error....7258
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error....7260
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error....7262
FAILURE CODE [CA2357] EGR Valve Servo Error....7264
FAILURE CODE [CA2381] KVGT Position Sensor High Error....7265
FAILURE CODE [CA2382] KVGT Position Sensor Low Error....7267
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error....7269
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error....7271
FAILURE CODE [CA2387] KVGT Servo Error....7273
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error....7274
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error....7277
FAILURE CODE [CA2637] KDOC Face Plugging....7279
FAILURE CODE [CA2639] Manual Stationary Regeneration Request....7281
FAILURE CODE [CA2732] Fuel Doser Solenoid 2 High Error....7284
FAILURE CODE [CA2733] Fuel Doser Solenoid 2 Low Error....7286
FAILURE CODE [CA2741] Fuel Dozer Solenoid Valve Swap Error....7288
FAILURE CODE [CA2765] Injector Trim Data Mismatch....7289
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error....7290
FAILURE CODE [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable....7296
FAILURE CODE [CA2878] Fuel Doser Solenoid 2 Servo Error....7299
FAILURE CODE [CA2881] Dosing Fuel Pressure Low Error 1....7302
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error....7305
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error....7307
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error....7309
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error....7311
FAILURE CODE [CA3142] SCR Temperature Sensor High Error....7315
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error....7316
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error....7317
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error....7320
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error....7321
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error....7322
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2....7324
FAILURE CODE [CA3165] SCR Outlet Temperature High Error....7330
FAILURE CODE [CA3167] Fuel Doser Degradation....7332
FAILURE CODE [CA3229] SCR Temperature High Error....7335
FAILURE CODE [CA3231] SCR Temperature High Error - Non Regeneration....7337
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error....7339
FAILURE CODE [CA3235] SCR Outlet Temperature High Error - Non Regeneration....7343
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error....7345
FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error....7348
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error....7351
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error....7354
FAILURE CODE [CA3253] KDOC Temperature Error - Non Regeneration....7356
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1....7359
FAILURE CODE [CA3255] KDPF Temperature Error - Non Regeneration....7362
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1....7365
FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2....7367
FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2....7369
FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error....7372
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error....7374
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error....7375
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error....7378
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error....7379
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error....7380
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error....7383
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error....7384
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error....7386
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error....7389
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error....7391
FAILURE CODE [CA3497] AdBlue/DEF Level Low Error 1....7393
FAILURE CODE [CA3498] AdBlue/DEF Level Low Error 2....7394
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low)....7395
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error....7402
FAILURE CODE [CA3547] AdBlue/DEF Level Low Error 4....7404
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error....7405
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error....7407
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error....7409
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error....7411
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error....7414
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction....7417
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error....7421
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error....7423
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error....7425
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error....7427
FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error....7429
FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error....7431
FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 1....7433
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Error....7439
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error....7441
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error....7443
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error....7445
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error....7450
FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error....7456
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error....7459
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error....7460
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error....7461
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error....7464
FAILURE CODE [CA3751] SCR Catalyst Degradation Error....7467
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error....7469
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2....7471
FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 1....7474
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error....7477
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error....7481
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error....7483
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error....7487
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error....7489
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error....7491
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error....7493
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error....7496
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error....7498
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error....7500
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error....7504
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error....7508
FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error....7511
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction....7514
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error....7516
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error....7517
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error....7518
FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error....7521
FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error....7524
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error....7527
FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error....7529
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error....7531
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error....7533
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error....7536
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error....7538
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error....7541
FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error....7543
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error....7545
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error....7548
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error....7551
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error....7554
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error....7557
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error....7560
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error....7563
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error....7567
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data Error....7568
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error....7569
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error....7570
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible....7572
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error....7575
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine Controller)....7578
FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error....7580
FAILURE CODE [CA5179] Engine Room Temperature Sensor High Error....7583
FAILURE CODE [CA5181] Engine Room Temperature Sensor Low Error....7585
FAILURE CODE [CA5383] Ash Accumulation High Error....7587
FAILURE CODE [D150KA] Secondary S/T Motor Relay Output Open Circuit....7589
FAILURE CODE [D150KB] Secondary S/T Motor Relay Output Ground Fault....7591
FAILURE CODE [D150KY] Secondary S/T Motor Relay Output Hot Short Circuit....7593
FAILURE CODE [D160KA] Backup Lamp Relay Output Open Circuit....7595
FAILURE CODE [D160KB] Backup Lamp Relay Output Ground Fault....7597
FAILURE CODE [D160KY] Backup Lamp Relay Output Hot Short Circuit....7599
FAILURE CODE [D191KA] Neutral Relay Output Open Circuit....7601
FAILURE CODE [D191KB] Neutral Relay Output Ground Fault....7604
FAILURE CODE [D191KY] Neutral Relay Output Hot Short Circuit....7607
FAILURE CODE [D192KA] ECSS Solenoid Open Circuit....7609
FAILURE CODE [D192KB] ECSS Solenoid Ground Fault....7611
FAILURE CODE [D192KY] ECSS Solenoid Hot Short Circuit....7613
FAILURE CODE [D19JKZ] Personal Code Relay Open Circuit or Short Circuit....7615
FAILURE CODE [D1E6KA] Parking Brake Relay Open Circuit....7617
FAILURE CODE [D1E6KB] Parking Brake Relay Ground Fault....7619
FAILURE CODE [D1E6KY] Parking Brake Relay Hot Short Circuit....7621
FAILURE CODE [D5ZHKA] Key SW C Terminal Signal Open Circuit or Ground Fault....7623
FAILURE CODE [D5ZHKB] Key SW C Terminal Signal Short Circuit....7625
FAILURE CODE [D5ZHKZ] Key SW C Terminal Signal Open Circuit or Short Circuit....7627
FAILURE CODE [D5ZHL6] Key SW C Terminal Signal Mismatch....7630
FAILURE CODE [D811MC] KOMTRAX Malfunction....7632
FAILURE CODE [D862KA] GPS Antenna Open Circuit....7633
FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX)....7634
FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX)....7636
FAILURE CODE [D8AQK4] CAN 2 Uncontrolled Communication (KOMTRAX)....7638
FAILURE CODE [D8AQKR] CAN 2 Defective Communication (KOMTRAX)....7639
FAILURE CODE [DAF0KT] Monitor Nonvolatile Memory Abnormality....7641
FAILURE CODE [DAF0MB] Monitor ROM Abnormality....7642
FAILURE CODE [DAF0MC] Monitor Malfunction....7643
FAILURE CODE [DAF3KK] Main Power Voltage Low Error (Monitor)....7644
FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit....7646
FAILURE CODE [DAFDKB] 12V Power Output Hot Short Circuit or Ground Fault (Monitor)....7648
FAILURE CODE [DAFGMC] GPS Module Malfunction....7650
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor)....7651
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor)....7653
FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Monitor)....7655
FAILURE CODE [DAQ0KK] Main Power Voltage Low Error (T/M Controller)....7656
FAILURE CODE [DAQ0KT] Read Only Memory Abnormality (T/M Controller)....7659
FAILURE CODE [DAQ0MC] T/M Controller Malfunction....7660
FAILURE CODE [DAQ1KA] Key SW ACC Signal Open Circuit (T/M Controller)....7661
FAILURE CODE [DAQ2KK] Solenoid Power Voltage Low Error (T/M Controller)....7663
FAILURE CODE [DAQ4KB] Self-holding Relay Output Ground Fault (T/M Controller)....7666
FAILURE CODE [DAQ9KQ] Model Selection Signal Mismatch (T/M Controller)....7668
FAILURE CODE [DAQLKA] System Operating Lamp Open Circuit (T/M Controller)....7669
FAILURE CODE [DAQLKB] System Operating Lamp Short Circuit (T/M Controller)....7671
FAILURE CODE [DAQQKR] CAN2 Defective Communication (T/M Controller)....7673
FAILURE CODE [DAQRKR] CAN1 Defective Communication (T/M Controller)....7674
FAILURE CODE [DAQRMA] Option Selection Mismatch (T/M Controller)....7675
FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C)....7676
FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C ECU)....7677
FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine Controller)....7678
FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine Controller)....7683
FAILURE CODE [DB90KK] Main Power Voltage Low Error (W/E Controller)....7689
FAILURE CODE [DB90KT] Read Only Memory Abnormality (W/E Controller)....7692
FAILURE CODE [DB90MC] W/E Controller Malfunction....7693
FAILURE CODE [DB91KA] Key SW ACC Signal Open Circuit (W/E Controller)....7694
FAILURE CODE [DB92KK] Solenoid Power Voltage Low Error (W/E Controller)....7696
FAILURE CODE [DB95KX] Failure of 5V Power Source 1....7699
FAILURE CODE [DB96KX] 5V Sensor Power Supply 2 Voltage out of Range (W/E Controller)....7702
FAILURE CODE [DB99KQ] Model Selection Signal Mismatch (W/E Controller)....7704
FAILURE CODE [DB9LKA] System Operating Lamp Open Circuit (W/E Controller)....7705
FAILURE CODE [DB9LKB] System Operating Lamp Short Circuit (W/E Controller)....7707
FAILURE CODE [DB9QKR] CAN 2 Defective Communication (W/E Controller)....7709
FAILURE CODE [DB9RKR] CAN 1 Defective Communication (W/E Controller)....7710
FAILURE CODE [DB9RMA] Option Selection Mismatch (W/E Controller)....7711
FAILURE CODE [DBE5KX] 5V Sensor Power Supply Voltage out of Range (T/M Controller)....7712
FAILURE CODE [DBE6KX] 24V Sensor Power Supply Ground Fault (T/M Controller)....7714
FAILURE CODE [DD1ALD] Remote Positioner Set SW Ground Fault....7716
FAILURE CODE [DDAAL6] Engine Shutdown Secondary SW Signal Open Circuit....7718
FAILURE CODE [DDB6L4] Neutrizer Signal Mismatch....7720
FAILURE CODE [DDD1LD] Bucket Positioner Set SW Ground Fault....7723
FAILURE CODE [DDK3KA] Directional SW Signal Open Circuit (S/T Wheel Specification)....7725
FAILURE CODE [DDK3KB] Directional SW Signal Short Circuit (S/T Wheel Specification)....7728
FAILURE CODE [DDK6KA] Directional Lever Signal Open Circuit....7731
FAILURE CODE [DDK6KB] Directional Lever Signal Short Circuit....7734
FAILURE CODE [DDKLKA] Failure of J/S ON/OFF Switch....7736
FAILURE CODE [DDKLKB] Hot Short of J/S ON/OFF Switch....7739
FAILURE CODE [DDNRKY] W/E Lock SW Hot Short Circuit....7741
FAILURE CODE [DDT0L4] Shift Mode Select SW Signal Hot Short Circuit....7743
FAILURE CODE [DDT4LD] T/M Cut off Set SW Ground Fault....7745
FAILURE CODE [DDT9LD] T/M Cut off SW Ground Fault....7747
FAILURE CODE [DDTALD] Ground Fault of Torque Converter Lock Up SW....7749
FAILURE CODE [DDW9LD] Kickdown SW Ground Fault....7751
FAILURE CODE [DDWLLD] T/M Shift Hold SW Ground Fault....7753
FAILURE CODE [DF10KA] T/M Shift Lever Input Signal Open Circuit....7755
FAILURE CODE [DF10KB] T/M Shift Lever Input Signal Short Circuit....7758
FAILURE CODE [DGF1KA] T/M Oil Temperature Sensor Open Circuit....7761
FAILURE CODE [DGF1KB] T/M Oil Temperature Sensor Ground Fault....7763
FAILURE CODE [DGH2KX] Hydraulic Oil Temperature Sensor Input Signal Out of Range....7765
FAILURE CODE [DGR2KB] Brake Oil Temperature Sensor Ground Fault (Rear)....7767
FAILURE CODE [DGR2KZ] Brake Oil Temperature Sensor Open Circuit or Hot Short Circuit (Rear)....7769
FAILURE CODE [DGT1KA] T/C Oil Temperature Sensor Open Circuit....7771
FAILURE CODE [DGT1KB] T/C Oil Temperature Sensor Ground Fault....7773
FAILURE CODE [DH21KA] Loader Pump Pressure Sensor Open Circuit or Ground Fault....7775
FAILURE CODE [DH21KB] Loader Pump Pressure Sensor Short Circuit....7778
FAILURE CODE [DHA4KA] Air Cleaner Clogging Sensor Open Circuit....7780
FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Frozen....7782
FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen....7784
FAILURE CODE [DHPCKX] Boom Cylinder Pressure Sensor Input Signal Out of Range (Bottom)....7786
FAILURE CODE [DHPDKX] Boom Cylinder Pressure Sensor Input Signal Out of Range (Head)....7789
FAILURE CODE [DHT1KX] T/M Cut Off Pressure Sensor Input Signal Out of Range....7792
FAILURE CODE [DHT5KX] T/C Oil Pressure Sensor Input Signal Out of Range (Inlet)....7795
FAILURE CODE [DHT7KX] T/C Oil Pressure Sensor Input Signal Out of Range (Outlet)....7798
FAILURE CODE [DHT8KA] S/T Oil Pressure Sensor Open Circuit or Ground Fault....7801
FAILURE CODE [DHT8KB] S/T Oil Pressure Sensor Short Circuit....7804
FAILURE CODE [DHT8ZG] S/T Oil Pressure Low....7806
FAILURE CODE [DHUDKA] Secondary S/T Pump Pressure Sensor Open Circuit or Ground Fault....7807
FAILURE CODE [DHUDKB] Secondary S/T Pump Pressure Sensor Short Circuit....7810
FAILURE CODE [DJF1KA] Fuel Level Sensor Open Circuit....7812
FAILURE CODE [DK55KA] Directional Lever Potentiometer Open Circuit or Groud Fault....7814
FAILURE CODE [DK55KY] Directional Lever Potentiometer Hot Short Circuit....7817
FAILURE CODE [DK55L5] Directional Lever SW and Potentiometer Input Signal Mispatch....7819
FAILURE CODE [DK59KA] Boom Lever Potentiometer Open Circuit or Ground Fault (Main)....7820
FAILURE CODE [DK59KY] Boom Lever Potentiometer Hot Short Circuit (Main)....7824
FAILURE CODE [DK59L8] Boom Lever Potentiometer Main or Sub Signal Abnormality....7828
FAILURE CODE [DK5AKA] Boom Lever Potentiometer Open Circuit or Ground Fault (Sub)....7833
FAILURE CODE [DK5AKY] Boom Lever Potentiometer Hot Short Circuit (Sub)....7837
FAILURE CODE [DK5BKA] Bucket Lever Potentiometer Open Circuit or Ground Fault (Main)....7841
FAILURE CODE [DK5BKY] Bucket Lever Potentiometer Hot Short Circuit (Main)....7845
FAILURE CODE [DK5BL8] Bucket Lever Potentiometer Main or Sub Signal Abnormality....7849
FAILURE CODE [DK5CKA] Bucket Lever Potentiometer Open Circuit or Ground Fault (Sub)....7853
FAILURE CODE [DK5CKY] Bucket Lever Potentiometer Hot Short Circuit (Sub)....7857
FAILURE CODE [DK5DKA] 3rd Lever Potentiometer Open Circuit or Ground Fault (Main)....7861
FAILURE CODE [DK5DKY] 3rd Lever Potentiometer Hot Short Circuit (Main)....7864
FAILURE CODE [DK5DL8] 3rd Lever Potentiometer Main or Sub Signal Abnormality....7867
FAILURE CODE [DK5EKA] 3rd Lever Potentiometer Open Circuit or Ground Fault (Sub)....7871
FAILURE CODE [DK5EKY] 3rd Lever Potentiometer Hot Short Circuit (Sub)....7874
FAILURE CODE [DKA0KA] Boom Angle Sensor Open Circuit or Ground Fault....7877
FAILURE CODE [DKA0KY] Boom Angle Sensor Hot Short Circuit....7880
FAILURE CODE [DKA0L0] Boom Angle Sensor Dislocation....7883
FAILURE CODE [DKA1KA] Bucket Angle Sensor Open Circuit or Ground Fault....7886
FAILURE CODE [DKA1KY] Bucket Angle Sensor Hot Short Circuit....7889
FAILURE CODE [DLF1KA] T/M Input Speed Sensor Open Circuit....7891
FAILURE CODE [DLF1LC] T/M Input Speed Sensor Hot Short Circuit or Ground Fault....7893
FAILURE CODE [DLM3KA] Radiator Fan Speed Sensor Open Circuit or Hot Short Circuit....7895
FAILURE CODE [DLM3LC] Radiator Fan Speed Sensor Signal Abnormality....7897
FAILURE CODE [DLT3KA] T/M Output Speed Sensor Open Circuit (Main)....7899
FAILURE CODE [DLT3LC] T/M Output Speed Sensor Signal Abnormality (Main)....7901
FAILURE CODE [DPQ1KR] LIN Defective Communication (Switch Panel)....7903
FAILURE CODE [DPQ2KR] LIN Defective Communication (LED Unit)....7906
FAILURE CODE [DPQ3KR] LIN Defective Communication (Rearview Monitor)....7909
FAILURE CODE [DSJ0KR] CAN 2 Defective Communication (Meter Unit)....7912
FAILURE CODE [DT20KB] T/M Cut Off Indicator Output Ground Fault....7915
FAILURE CODE [DT22KB] W/E Lock SW Indicator Ground Fault....7917
FAILURE CODE [DT23KB] J/S Effective Indicator Output Ground Fault....7919
FAILURE CODE [DV00KB] Buzzer Output Ground Fault....7921
FAILURE CODE [DW4PKA] Boom RAISE EPC Solenoid Open Circuit....7923
FAILURE CODE [DW4PKB] Boom RAISE EPC Solenoid Ground Fault....7925
FAILURE CODE [DW4PKY] Boom RAISE EPC Solenoid Hot Short Circuit....7927
FAILURE CODE [DW4QKA] Boom LOWER EPC Solenoid Open Circuit....7929
FAILURE CODE [DW4QKB] Boom LOWER EPC Solenoid Ground Fault....7931
FAILURE CODE [DW4QKY] Boom LOWER EPC Solenoid Hot Short Circuit....7933
FAILURE CODE [DW4RKA] Bucket TILT EPC Solenoid Open Circuit....7935
FAILURE CODE [DW4RKB] Bucket TILT EPC Solenoid Ground Fault....7937
FAILURE CODE [DW4RKY] Bucket TILT EPC Solenoid Hot Short Circuit....7939
FAILURE CODE [DW4SKA] Bucket DUMP EPC Solenoid Open Circuit....7941
FAILURE CODE [DW4SKB] Bucket DUMP EPC Solenoid Ground Fault....7943
FAILURE CODE [DW4SKY] Bucket DUMP EPC Solenoid Hot Short Circuit....7945
FAILURE CODE [DW7BKA] Radiator Fan Reverse Solenoid Open Circuit....7947
FAILURE CODE [DW7BKB] Radiator Fan Reverse Solenoid Ground Fault....7949
FAILURE CODE [DW7BKY] Radiator Fan Reverse Solenoid Hot Short Circuit....7951
FAILURE CODE [DWM1KA] W/E Neutral Lock Solenoid Open Circuit....7953
FAILURE CODE [DWM1KB] W/E Neutral Lock Solenoid Ground Fault....7955
FAILURE CODE [DWM1KY] W/E Neutral Lock Solenoid Hot Short Circuit....7957
FAILURE CODE [DWN6KA] Boom Detent Solenoid Open Circuit....7959
FAILURE CODE [DWN6KB] Boom Detent Solenoid Ground Fault....7961
FAILURE CODE [DWN6KY] Boom Detent Solenoid Hot Short Circuit....7963
FAILURE CODE [DWN8KA] Bucket Detent Solenoid Open Circuit....7966
FAILURE CODE [DWN8KB] Bucket Detent Solenoid Ground Fault....7968
FAILURE CODE [DWN8KY] Bucket Detent Solenoid Hot Short Circuit....7970
FAILURE CODE [DX16KA] Radiator Fan Pump EPC Solenoid Open Circuit....7972
FAILURE CODE [DX16KB] Radiator Fan Pump EPC Solenoid Ground Fault....7974
FAILURE CODE [DX16KY] Radiator Fan Pump EPC Solenoid Hot Short Circuit....7976
FAILURE CODE [DXA1KA] Loader Pump EPC Solenoid Open Circuit....7978
FAILURE CODE [DXA1KB] Loader Pump EPC Solenoid Ground Fault....7980
FAILURE CODE [DXA1KY] Loader Pump EPC Solenoid Hot Short Circuit....7982
FAILURE CODE [DXANKA] S/T Pump EPC Solenoid Open Circuit....7984
FAILURE CODE [DXANKB] S/T Pump EPC Solenoid Ground Fault....7986
FAILURE CODE [DXANKY] S/T Pump EPC Solenoid Hot Short Circuit....7988
FAILURE CODE [DXH1KA] ECMV Solenoid Open Circuit (Lockup Clutch)....7990
FAILURE CODE [DXH1KB] ECMV Solenoid Ground Fault (Lockup Clutch)....7992
FAILURE CODE [DXH1KY] ECMV Solenoid Hot Short Circuit (Lockup Clutch)....7994
FAILURE CODE [DXH4KA] ECMV Solenoid Open Circuit (1st Clutch)....7996
FAILURE CODE [DXH4KB] ECMV Solenoid Ground Fault (1st Clutch)....7998
FAILURE CODE [DXH4KY] ECMV Solenoid Hot Short Circuit (1st Clutch)....8000
FAILURE CODE [DXH5KA] ECMV Solenoid Open Circuit (2nd Clutch)....8002
FAILURE CODE [DXH5KB] ECMV Solenoid Ground Fault (2nd Clutch)....8004
FAILURE CODE [DXH5KY] ECMV Solenoid Hot Short Circuit (2nd Clutch)....8006
FAILURE CODE [DXH6KA] ECMV Solenoid Open Circuit (3rd Clutch)....8008
FAILURE CODE [DXH6KB] ECMV Solenoid Ground Fault (3rd Clutch)....8010
FAILURE CODE [DXH6KY] ECMV Solenoid Hot Short Circuit (3rd Clutch)....8012
FAILURE CODE [DXH7KA] ECMV Solenoid Open Circuit (Reverse Clutch)....8014
FAILURE CODE [DXH7KB] ECMV Solenoid Ground Fault (Reverse Clutch)....8016
FAILURE CODE [DXH7KY] ECMV Solenoid Hot Short Circuit (Reverse Clutch)....8018
FAILURE CODE [DXH8KA] ECMV Solenoid Open Circuit (Forward Clutch)....8020
FAILURE CODE [DXH8KB] ECMV Solenoid Ground Fault (Forward Clutch)....8022
FAILURE CODE [DXH8KY] ECMV Solenoid Hot Short Circuit (Forward Clutch)....8024
FAILURE CODE [DXHHKA] ECMV Solenoid Open Circuit (4th Clutch)....8026
FAILURE CODE [DXHHKB] ECMV Solenoid Ground Fault (4th Clutch)....8028
FAILURE CODE [DXHHKY] ECMV Solenoid Hot Short Circuit (4th Clutch)....8030
FAILURE CODE [DXHJKA] 3rd Spool Extend EPC Solenoid Open Circuit....8032
FAILURE CODE [DXHJKB] 3rd Spool Extend EPC Solenoid Ground Fault....8034
FAILURE CODE [DXHJKY] 3rd Spool Extend EPC Solenoid Hot Short Circuit....8036
FAILURE CODE [DXHKKA] 3rd Spool Retract EPC Solenoid Open Circuit....8038
FAILURE CODE [DXHKKB] 3rd Spool Retract EPC Solenoid Ground Fault....8040
FAILURE CODE [DXHKKY] 3rd Spool Retract EPC Solenoid Hot Short Circuit....8042
FAILURE CODE [DY30MA] Secondary S/T Release Trouble....8044
FAILURE CODE [DY30MC] Secondary S/T Defective Activation....8048
FAILURE CODE [DY30ME] Secondary S/T Long Time Activated....8053
FAILURE CODE [LA00L3] Fan Reverse Defective Control....8055
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)....8056
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)....8056
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK....8064
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK....8067
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP....8070
E-5 ALL OF LCD UNIT, LED UNIT AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING....8072
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING....8075
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL (BACKLIGHT GOES OUT OR FLICKERS)....8078
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY....8081
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL....8084
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL....8087
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL....8091
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCHES DOES NOT OPERATE PROPERLY....8093
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION....8096
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL....8100
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY....8104
E-16 REAR VIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS....8105
E-17 REAR VIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY....8108
E-18 REAR VIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED....8111
E-19 NIGHT LIGHTING LAMP OF REAR VIEW MONITOR IS ABNORMAL....8115
E-20 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP....8117
E-21 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP....8119
E-22 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION....8121
E-23 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP....8125
E-24 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP....8126
E-25 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL....8127
E-26 TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP....8129
E-27 INDICATION OF HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT....8130
E-28 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL....8132
E-29 ALARM BUZZER DOES NOT SOUND....8133
E-30 ALARM BUZZER DOES NOT STOP SOUNDING....8135
E-31 KICKDOWN DOES NOT WORK WHEN KICKDOWN SWITCH IS TURNED ON....8136
E-32 HOLD SWITCH DOES NOT WORK WHEN IT IS PRESSED....8138
E-33 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED....8140
E-34 TRANSMISSION CUT-OFF MODE IS NOT SELECTED OR NOT RELEASED....8144
E-35 TRANSMISSION CUT-OFF SETTING CANNOT BE RELEASED....8146
E-36 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED....8148
E-37 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE NORMALLY WHEN ENGINE POWER MODE SELECTOR SWITCH IS OPERATED....8150
E-38 FLOW OF LOADER PUMP DOES NOT INCREASE FROM THE MINIMUM RATE....8152
E-39 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED....8153
E-40 HORN DOES NOT SOUND....8155
E-41 HORN DOES NOT STOP SOUNDING....8158
E-42 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS....8160
E-43 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT....8162
E-44 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT....8166
E-45 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT....8170
E-46 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT....8172
E-47 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT....8174
E-48 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT....8179
E-49 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT....8184
E-50 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT....8187
E-51 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT....8190
E-52 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED....8194
E-53 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT....8198
E-54 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND....8202
E-55 FRONT WIPER DOES NOT OPERATE....8204
E-56 REAR WIPER DOES NOT OPERATE....8208
E-57 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY....8211
E-58 WIND WASHER DOES NOT OPERATE....8213
E-59 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY....8216
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)....8217
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)....8217
FAILURE MODE AND CAUSE TABLE....8218
H-1 MACHINE DOES NOT START....8232
H-2 LOCKUP IS NOT RELEASED....8235
H-3 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE....8236
H-4 TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADABILITY IS LOW, OR GEAR SPEED DOES NOT SHIFT....8237
H-5 LARGE SHOCK IS MADE WHEN MACHINE MOVES OFF OR GEAR IS SHIFTED....8240
H-6 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED....8243
H-7 OPERATING WORK EQUIPMENT CAUSES ENGINE SPEED TO LOWER SIGNIFICANTLY OR ENGINE TO STALL....8246
H-8 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE....8247
H-9 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS....8248
H-10 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES....8251
H-11 MACHINE DOES NOT TURN....8252
H-12 TURNING RESPONSE IS POOR....8254
H-13 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS....8256
H-14 TURNING RADIUS DIFFERS BETWEEN RIGHT AND LEFT TURNS....8258
H-15 STEERING WHEEL IS HEAVY....8259
H-16 WHEEL BRAKES DO NOT WORK OR ARE WEAK....8261
H-17 WHEEL BRAKES ARE NOT RELEASED OR DRAG....8263
H-18 PARKING BRAKE DOES NOT WORK OR IT IS WEAK....8264
H-19 PARKING BRAKE IS NOT RELEASED OR DRAGS....8265
H-20 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH....8266
H-21 BOOM MOVES UP AND DOWN DURING OPERATION....8269
H-22 BOOM DOES NOT RISE....8270
H-23 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE....8273
H-24 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT....8276
H-25 BUCKET DOES NOT STOP AT THE POSITION WHICH IS SET WITH REMOTE BUCKET POSITIONER....8277
H-26 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND....8278
H-27 HYDRAULIC DRIFT OF BOOM IS LARGE....8280
H-28 HYDRAULIC DRIFT OF BUCKET IS LARGE....8281
H-29 BUCKET DOES NOT TILT BACK....8282
H-30 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE....8285
H-31 BUCKET DECELERATES DURING TILT-BACK OPERATION....8288
H-32 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND....8289
H-33 E.C.S.S. (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES....8291
H-34 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD)....8292
H-35 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)....8293
H-36 UNUSUAL NOISE IS HEARD FROM AROUND FAN....8295
TROUBLESHOOTING OF ENGINE (S-MODE)....8296
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)....8296
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION....8297
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT....8298
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)....8299
S-4 ENGINE STARTABILITY IS POOR....8300
S-5 ENGINE DOES NOT PICK UP SMOOTHLY....8302
S-6 ENGINE STOPS DURING OPERATION....8304
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE....8306
S-8 ENGINE LACKS POWER....8307
S-9 KDPF GETS CLOGGED IN A SHORT TIME....8309
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE....8311
S-11 OIL BECOMES CONTAMINATED QUICKLY....8312
S-12 FUEL CONSUMPTION IS EXCESSIVE....8313
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)....8314
S-14 OIL PRESSURE DROPS....8315
S-15 FUEL MIXES INTO ENGINE OIL....8317
S-16 WATER MIXES INTO ENGINE OIL (MILKY)....8318
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)....8319
S-18 UNUSUAL NOISE IS HEARD....8320
S-19 VIBRATION IS EXCESSIVE....8321
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT....8322
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY....8323
S-22 ACTIVE REGENERATION TAKES TIME....8325
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION....8326
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE....8327
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)....8329
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)....8330
50 DISASSEMBLY AND ASSEMBLY....8332
CONTENTS....8333
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY....8337
HOW TO READ THIS MANUAL....8337
COATING MATERIALS LIST....8338
SPECIAL TOOLS LIST....8343
SKETCHES OF SPECIAL TOOLS....8363
ENGINE AND COOLING SYSTEM....8386
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY....8386
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY....8386
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY....8390
REMOVE AND INSTALL INJECTOR ASSEMBLY....8396
METHOD FOR REMOVING INJECTOR ASSEMBLY....8396
METHOD FOR INSTALLING INJECTOR ASSEMBLY....8400
REMOVE AND INSTALL FUEL DOSER ASSEMBLY....8408
METHOD FOR REMOVING FUEL DOSER ASSEMBLY....8408
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY....8409
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY....8412
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY....8412
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY....8423
REMOVE AND INSTALL EGR VALVE ASSEMBLY....8440
METHOD FOR REMOVING EGR VALVE ASSEMBLY....8440
METHOD FOR INSTALLING EGR VALVE ASSEMBLY....8440
REMOVE AND INSTALL EGR COOLER ASSEMBLY....8442
METHOD FOR REMOVING EGR COOLER ASSEMBLY....8442
METHOD FOR INSTALLING EGR COOLER ASSEMBLY....8444
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY....8447
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY....8447
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY....8448
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT....8450
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT....8450
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT....8452
REMOVE AND INSTALL ALTERNATOR BELT....8455
METHOD FOR REMOVING ALTERNATOR BELT....8455
METHOD FOR INSTALLING ALTERNATOR BELT....8456
REMOVE AND INSTALL RADIATOR ASSEMBLY....8458
METHOD FOR REMOVING RADIATOR ASSEMBLY....8458
METHOD FOR INSTALLING RADIATOR ASSEMBLY....8463
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY....8468
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY....8468
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY....8471
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY....8473
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY....8473
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY....8475
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY....8477
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY....8477
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY....8481
REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY....8485
METHOD FOR REMOVING POWER TRAIN OIL COOLER ASSEMBLY....8485
METHOD FOR INSTALLING POWER TRAIN OIL COOLER ASSEMBLY....8490
REMOVE AND INSTALL ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY....8496
METHOD FOR REMOVING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY....8497
METHOD FOR INSTALLING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY....8510
DISCONNECT AND CONNECT ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY....8523
METHOD FOR DISCONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY....8523
METHOD FOR CONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY....8524
REMOVE AND INSTALL ENGINE FRONT OIL SEAL....8526
METHOD FOR REMOVING ENGINE FRONT OIL SEAL....8526
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL....8528
REMOVE AND INSTALL ENGINE REAR OIL SEAL....8531
METHOD FOR REMOVING ENGINE REAR OIL SEAL....8531
METHOD FOR INSTALLING ENGINE REAR OIL SEAL....8532
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY....8539
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY....8539
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY....8545
REMOVE AND INSTALL FUEL TANK ASSEMBLY....8552
METHOD FOR REMOVING FUEL TANK ASSEMBLY....8552
METHOD FOR INSTALLING FUEL TANK ASSEMBLY....8555
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY....8560
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY....8560
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY....8564
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY....8568
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY....8568
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY....8573
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR....8577
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR....8577
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR....8577
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER....8579
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER....8579
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER....8579
REMOVE AND INSTALL KDPF ASSEMBLY....8580
METHOD FOR REMOVING KDPF ASSEMBLY....8580
METHOD FOR INSTALLING KDPF ASSEMBLY....8583
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY....8587
METHOD FOR DISASSEMBLING KDPF ASSEMBLY....8587
METHOD FOR ASSEMBLING KDPF ASSEMBLY....8591
REMOVE AND INSTALL SCR ASSEMBLY....8596
METHOD FOR REMOVING SCR ASSEMBLY....8597
METHOD FOR INSTALLING SCR ASSEMBLY....8606
REMOVE AND INSTALL KDPF, SCR ASSEMBLY....8617
METHOD FOR REMOVING KDPF, SCR ASSEMBLY....8618
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY....8625
REMOVE AND INSTALL KCCV ASSEMBLY....8633
METHOD FOR REMOVING KCCV ASSEMBLY....8633
METHOD FOR INSTALLING KCCV ASSEMBLY....8633
REMOVE AND INSTALL KVGT ASSEMBLY....8635
METHOD FOR REMOVING KVGT ASSEMBLY....8635
METHOD FOR INSTALLING KVGT ASSEMBLY....8641
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE....8647
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE....8647
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE....8653
REMOVE AND INSTALL AdBlue/DEF INJECTOR....8661
METHOD FOR REMOVING AdBlue/DEF INJECTOR....8661
METHOD FOR INSTALLING AdBlue/DEF INJECTOR....8665
REMOVE AND INSTALL AdBlue/DEF PUMP....8669
METHOD FOR REMOVING AdBlue/DEF PUMP....8669
METHOD FOR INSTALLING AdBlue/DEF PUMP....8672
REMOVE AND INSTALL AdBlue/DEF HOSE....8675
METHOD FOR REMOVING AdBlue/DEF HOSE....8676
METHOD FOR INSTALLING AdBlue/DEF HOSE....8685
REMOVE AND INSTALL AIR CLEANER ASSEMBLY....8696
METHOD FOR REMOVING AIR CLEANER ASSEMBLY....8696
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY....8697
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY....8699
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY....8699
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY....8700
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY....8702
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY....8702
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY....8703
POWER TRAIN....8705
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY....8705
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY....8705
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY....8709
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY....8717
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY....8719
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY....8737
DISASSEMBLE AND ASSEMBLE TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY....8764
METHOD FOR DISASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY....8765
METHOD FOR ASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY....8781
REMOVE AND INSTALL FRONT AXLE ASSEMBLY....8801
METHOD FOR REMOVING FRONT AXLE ASSEMBLY....8801
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY....8803
REMOVE AND INSTALL REAR AXLE ASSEMBLY....8805
METHOD FOR REMOVING REAR AXLE ASSEMBLY....8805
METHOD FOR INSTALLING REAR AXLE ASSEMBLY....8811
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY....8818
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY....8819
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY....8824
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY....8832
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY....8833
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY....8842
STEERING SYSTEM....8861
REMOVE AND INSTALL STEERING VALVE ASSEMBLY....8861
METHOD FOR REMOVING STEERING VALVE ASSEMBLY....8861
METHOD FOR INSTALLING STEERING VALVE ASSEMBLY....8863
BRAKE SYSTEM....8866
REMOVE AND INSTALL PARKING BRAKE DISC AND PLATE....8866
METHOD FOR REMOVING PARKING BRAKE DISC AND PLATE....8866
METHOD FOR INSTALLING PARKING BRAKE DISC AND PLATE....8869
UNDERCARRIAGE AND FRAME....8872
REMOVE AND INSTALL CENTER HINGE PIN....8872
METHOD FOR REMOVING CENTER HINGE PIN....8872
METHOD FOR INSTALLING CENTER HINGE PIN....8878
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY....8885
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY....8885
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY....8887
REMOVE AND INSTALL FULL-LENGTH FENDER ASSEMBLY....8891
METHOD FOR REMOVING FULL-LENGTH FENDER ASSEMBLY....8891
METHOD FOR INSTALLING FULL-LENGTH FENDER ASSEMBLY....8892
HYDRAULIC SYSTEM....8893
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY....8893
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY....8893
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY....8897
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY....8901
METHOD FOR REMOVING WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY....8901
METHOD FOR INSTALLING WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY....8902
REMOVE AND INSTALL STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY....8904
METHOD FOR REMOVING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY....8904
METHOD FOR INSTALLING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY....8905
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY....8908
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY....8908
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY....8911
WORK EQUIPMENT....8915
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY....8915
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY....8915
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY....8919
DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLY....8924
METHOD FOR DISASSEMBLING HYDRAULIC CYLINDER ASSEMBLY....8925
METHOD FOR ASSEMBLING HYDRAULIC CYLINDER ASSEMBLY....8928
CAB AND ITS ATTACHMENTS....8934
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY....8934
METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY....8934
METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY....8939
REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS)....8944
METHOD FOR REMOVING OPERATOR'S CAB GLASS (ADHERED GLASS)....8944
METHOD FOR INSTALLING OPERATOR'S CAB GLASS (ADHERED GLASS)....8945
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY....8954
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY....8954
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY....8960
REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY....8965
METHOD FOR REMOVING OPERATOR'S SEAT ASSEMBLY....8965
METHOD FOR INSTALLING OPERATOR'S SEAT ASSEMBLY....8967
REMOVE AND INSTALL SEAT BELT....8969
METHOD FOR REMOVING SEAT BELT....8969
METHOD FOR INSTALLING SEAT BELT....8969
ELECTRICAL SYSTEM....8971
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY....8971
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY....8971
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY....8973
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY....8976
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY....8976
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY....8977
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY....8980
METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY....8980
METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY....8980
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY....8982
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY....8982
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY....8984
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY....8986
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY....8986
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY....8987
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR....8989
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR....8989
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR....8990
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR....8991
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR....8991
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR....8992
REMOVE AND INSTALL SCR TEMPERATURE SENSOR....8993
METHOD FOR REMOVING SCR TEMPERATURE SENSOR....8993
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR....8998
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY....9003
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY....9003
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY....9004
60 MAINTENANCE STANDARD....9006
CONTENTS....9007
ENGINE AND COOLING SYSTEM....9008
MAINTENANCE STANDARD OF ENGINE MOUNT....9008
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP....9009
MAINTENANCE STANDARD OF SERVO VALVE....9011
MAINTENANCE STANDARD OF COOLING FAN MOTOR....9012
POWER TRAIN....9014
MAINTENANCE STANDARD OF DRIVE SHAFT....9014
MAINTENANCE STANDARD OF TORQUE CONVERTER....9015
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV....9017
MAINTENANCE STANDARD OF TRANSMISSION....9018
MAINTENANCE STANDARD OF F, 1ST CLUTCH....9023
MAINTENANCE STANDARD OF R, 2ND CLUTCH....9024
MAINTENANCE STANDARD OF 3RD, 4TH CLUTCH....9026
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE....9028
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND CLUTCH ECMV....9030
MAINTENANCE STANDARD OF 3RD, 4TH CLUTCH ECMV....9031
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE....9032
MAINTENANCE STANDARD OF FRONT AXLE....9033
MAINTENANCE STANDARD OF REAR AXLE....9034
MAINTENANCE STANDARD OF FRONT CONVENTIONAL DIFFERENTIAL....9035
MAINTENANCE STANDARD OF REAR CONVENTIONAL DIFFERENTIAL....9038
MAINTENANCE STANDARD OF FRONT LIMITED SLIP DIFFERENTIAL....9041
MAINTENANCE STANDARD OF REAR LIMITED SLIP DIFFERENTIAL....9043
MAINTENANCE STANDARD OF FINAL DRIVE....9045
STEERING SYSTEM....9048
MAINTENANCE STANDARD OF STEERING COLUMN....9048
MAINTENANCE STANDARD OF STEERING PUMP....9049
MAINTENANCE STANDARD OF SERVO VALVE....9052
MAINTENANCE STANDARD OF STEERING VALVE....9053
MAINTENANCE STANDARD OF STEERING CYLINDER....9055
MAINTENANCE STANDARD OF SECONDARY STEERING PUMP....9057
BRAKE SYSTEM....9058
MAINTENANCE STANDARD OF CHARGE VALVE....9058
MAINTENANCE STANDARD OF SLACK ADJUSTER....9060
MAINTENANCE STANDARD OF FRONT BRAKE....9061
MAINTENANCE STANDARD OF REAR BRAKE....9062
MAINTENANCE STANDARD OF PARKING BRAKE....9063
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE....9065
UNDERCARRIAGE AND FRAME....9066
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN....9066
HYDRAULIC SYSTEM....9071
MAINTENANCE STANDARD OF HYDRAULIC TANK....9071
MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP....9073
MAINTENANCE STANDARD OF POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP....9075
MAINTENANCE STANDARD OF CONTROL VALVE....9076
WORK EQUIPMENT....9085
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE....9085
MAINTENANCE STANDARD OF BUCKET....9089
MAINTENANCE STANDARD OF LIFT CYLINDER....9090
MAINTENANCE STANDARD OF BUCKET CYLINDER....9091
80 APPENDIX....9092
CONTENTS....9093
AIR CONDITIONER SYSTEM....9095
PRECAUTIONS FOR REFRIGERANT....9095
AIR CONDITIONER COMPONENT....9096
SPECIFICATIONS OF AIR CONDITIONER....9098
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE....9099
OUTLINE OF REFRIGERATION CYCLE....9100
COMPONENT PARTS OF AIR CONDITIONER SYSTEM....9102
AIR CONDITIONER UNIT....9102
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT....9102
FUNCTION OF AIR CONDITIONER UNIT....9103
COMPONENT PARTS OF AIR CONDITIONER UNIT....9104
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT....9104
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT....9104
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT....9105
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT....9105
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT....9105
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT....9105
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT....9105
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT....9105
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT....9106
FUNCTION OF DUAL PRESSURE SWITCH....9106
AIR CONDITIONER CONTROLLER....9108
STRUCTURE OF AIR CONDITIONER CONTROLLER....9108
COMPRESSOR....9109
STRUCTURE OF COMPRESSOR....9109
SPECIFICATIONS OF COMPRESSOR....9109
FUNCTION OF COMPRESSOR....9109
CONDENSER....9110
STRUCTURE OF CONDENSER....9110
SPECIFICATIONS OF CONDENSER....9110
FUNCTION OF CONDENSER....9110
RECEIVER DRIER....9111
STRUCTURE OF RECEIVER DRIER....9111
SPECIFICATIONS OF RECEIVER DRIER....9111
FUNCTION OF RECEIVER DRIER....9111
SENSORS FOR AIR CONDITIONER SYSTEM....9112
FUNCTION OF SUNLIGHT SENSOR....9112
FUNCTION OF AMBIENT TEMPERATURE SENSOR....9112
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER....9113
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER....9115
AIR CONDITIONER SYSTEM DIAGRAM....9118
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER....9119
FUNCTION OF AIR CONDITIONER CONTROLLER....9120
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS....9121
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION....9127
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR....9128
CHECK TEMPERATURE CONTROL FUNCTION....9129
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION....9129
TEST VENT (MODE) CHANGEOVER....9131
METHOD FOR TESTING VENT (MODE) CHANGEOVER....9131
TESTING FRESH/RECIRC AIR CHANGEOVER....9133
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER....9133
TEST EVAPORATOR TEMPERATURE SENSOR....9135
TEST RELAYS....9137
METHOD FOR TESTING RELAYS....9137
AIR CONDITIONER TROUBLESHOOTING CHART 1....9139
AIR CONDITIONER TROUBLESHOOTING CHART 2....9140
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE....9143
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit....9145
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit....9147
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit....9149
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit....9151
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit....9153
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit....9155
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit....9157
FAILURE CODE [879EMC] Ventilation Damper Malfunction....9159
FAILURE CODE [879FMC] Air Mix Damper Malfunction....9162
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)....9165
A-2 TROUBLESHOOTING OF COMPRESSOR SYSTEM (AIR IS NOT COOLED)....9168
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)....9172
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER....9176
TROUBLESHOOTING USING GAUGE PRESSURE....9178
CONNECTION OF SERVICE TOOL....9180
METHOD FOR CONNECTING SERVICE TOOL....9181
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS....9182
HANDLE COMPRESSOR OIL....9184
90 CIRCUIT DIAGRAMS....9186
CONTENTS....9187
HYDRAULIC CIRCUIT DIAGRAM....9188
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM....9188
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM....9192
HYDRAULIC CIRCUIT DIAGRAM (1/2)....9194
HYDRAULIC CIRCUIT DIAGRAM (2/2)....9195
ELECTRICAL CIRCUIT DIAGRAM....9196
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM....9196
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/9)....9200
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/9)....9201
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/9)....9202
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/9)....9203
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/9)....9204
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/9)....9205
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/9)....9206
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/9)....9207
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/9)....9208
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (1/8)....9209
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (2/8)....9210
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (3/8)....9211
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (4/8)....9212
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (5/8)....9213
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (6/8)....9214
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (7/8)....9215
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (8/8)....9216
INDEX....9218
GEN00122-00 - Wheel Loader WA470-7 Field Assembly Instruction....9244
COVER....9244
CONTENTS....9245
0010 Setting of machine monitor....9247
0020 Deletion of electrical system abnormality record....9248
0030 Selection of options....9252
0040 Adjustment of work equipment controller boom angle....9257
0050 Adjustment of work equipment EPC lever detent position....9261
0060 Adjustment of work equipment EPC starting current....9266
0070 Adjustment of bucket positioner....9272
0080 Adjustment of rear view monitor guide line position....9276
SEBM006307 - Wheel Loader WA470-3 avance Shop Manual....9287
COVER....9287
CONTENTS....9288
01 GENERAL....9314
GENERAL ASSEMBLY DRAWING....9315
SPECIFICATIONS....9317
WEIGHT TABLE....9320
LIST OF LUBRICANT AND WATER....9322
10 STRUCTURE AND FUNCTION....9325
POWER TRAIN....9326
POWER TRAIN SYSTEM....9327
TORQUE CONVERTER, TRANSMISSION PIPING....9329
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM....9330
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM....9331
TORQUE CONVERTER....9333
TRANSMISSION....9336
TRANSMISSION CONTROL VALVE....9346
TRANSMISSION SOLENOID VALVE....9374
ELECTRONIC CONTROL MODULATION VALVE (ECMV)....9376
PILOT OIL FILTER....9379
DRIVE SHAFT....9380
AXLE....9381
DIFFERENTIAL....9383
LIMITED SLIP DIFFERENTIAL....9387
FINAL DRIVE....9391
AXLE MOUNT, CENTER HINGE PIN....9392
STEERING PIPING....9393
STEERING COLUMN....9394
STEERING VALVE....9395
ORBIT-ROLL VALVE....9409
STOP VALVE....9413
EMERGENCY STEERING PUMP....9414
DIVERTER VALVE....9415
BRAKE PIPING....9418
BRAKE HYDRAULIC CIRCUIT DIAGRAM....9419
BRAKE VALVE....9421
CHARGE VALVE....9426
ACCUMULATOR (FOR BRAKE)....9432
SLACK ADJUSTER....9433
BRAKE....9436
PARKING BRAKE CONTROL....9438
PARKING BRAKE....9439
PARKING BRAKE SOLENOID VALVE....9440
PARKING BRAKE VALVE....9441
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE....9442
HYDRAULIC PIPING....9443
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM....9444
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM....9445
WORK EQUIPMENT LEVER LINKAGE....9447
HYDRAULIC TANK....9448
PPC VALVE....9450
PPC RELIEF VALVE....9455
ACCUMULATOR (FOR PPC VALVE)....9456
CUT-OFF VALVE....9457
MAIN CONTROL VALVE....9460
WORK EQUIPMENT LINKAGE....9474
BUCKET....9476
BUCKET POSITIONER AND BOOM KICK-OUT....9477
CAB....9483
ROPS CAB....9486
AIR CONDITIONER....9488
ELECTRIC CIRCUIT DIAGRAM ....9489
MACHINE MONITOR SYSTEM....9509
MAIN MONITOR....9510
MAINTENANCE MONITOR....9515
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM....9518
WORK EQUIPMENT CONTROL SYSTEM....9532
E.C.S.S.(ELECTRONIC CONTROLLED SUSPENSION SYSTEM)(OPTION)....9539
E.C.S.S.SYSTEM(OPTION)....9543
SENSORS....9547
ENGINE STARTING CIRCUIT....9552
ENGINE STOP CIRCUIT....9553
PREHEATING CIRCUIT....9554
ELECTRIC TRANSMISSION CONTROL....9555
KICK-DOWN SWITCH....9558
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM....9559
TRANSMISSION CUT-OFF SWITCH....9568
TRANSMISSION CUT-OFF FUNCTION....9569
ELECTRIC PARKING BRAKE CONTROL ....9573
20 TESTING AND ADJUSTING ....9586
STANDARD VALUE TABLE FOR ENGINE....9587
STANDARD VALUE TABLE FOR CHASSIS....9588
STANDARD VALUE TABLE FOR ELECTRICAL PARTS....9591
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING....9596
MEASUREING ENGINE SPEED....9597
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)....9598
ADJUSTING VALVE CLEARANCE....9599
MEASURING EXHAUST COLOR....9600
MEASURING EXHAUST GAS TEMPERATURE....9601
MEASURING BLOW-BY PRESSURE....9602
MEASURING COMPRESSION PRESSURE....9603
MEASURING ENGINE OIL PRESSURE....9604
TESTING AND ADJUSTING FUEL INJECTION TIMING....9605
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE....9607
TESTING AND ADJUSTING FAN BELT TENSION....9609
MEASURING ACCELERATOR PEDAL....9610
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER....9612
MEASURING STALL SPEED....9613
MEASURING TORQUE CONVERTER, TRANSMISSION,PARKING BRAKE OIL PRESSURE....9615
METHOD OF OPERATING EMERGENCY MANUAL SPOOL....9617
MEASURING CLEARANCE BETWEEN TIRE AND WHEEL ....9619
TESTING AND ADJUSTING STEERING WHEEL ....9620
TESTING AND ADJUSTING STEERING CONTROL....9623
MEASURING STEERING OIL PRESSURE....9624
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL ....9626
TESTING BRAKE OIL PRESSURE....9627
MEASURING BRAKE PERFORMANCE....9628
MEASURING BRAKE DISC WEAR....9629
BLEEDING AIR FROM BRAKE SYSTEM....9630
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE....9631
MEASURING PARKING BRAKE PERFORMANCE....9632
MANUAL RELEASE METHOD FOR PARKING BRAKE....9633
TESTING WEAR OF PARKING BRAKE DISC....9634
MEASURING WORK EQUIPMENT CONTROL LEVER....9635
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE....9637
MEASURING WORK EQUIPMENT ....9641
TESTING AND ADJUSTING BUCKET POSITIONER....9643
TESTING AND ADJUSTING BOOM KICK-OUT....9644
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)....9646
CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR....9647
ADJUSTING BOOM, BUCKET ANGLE POTENTIOMETER....9648
TROUBLESHOOTING....9649
POINTS TO REMEMBER WHEN TROUBLESHOOTING....9650
SEQUENCE OF EVENTS IN TROUBLESHOOTING....9651
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE....9652
HANDLING CONNECTORS....9659
CHECKS BEFORE TROUBLESHOOTING....9660
METHOD OF USING TROUBLESHOOTING CHARTS....9661
CONNECTOR TYPES AND MOUNTING LOCATIONS....9669
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....9674
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)....9681
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)....9682
S-2 ENGINE DOES NOT START ....9683
(1) ENGINE DOES NOT TURN....9683
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)....9684
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)....9685
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)....9686
S-4 ENGINE STOPS DURING OPERATIONS....9687
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....9688
S-6 ENGINE LACKS OUTPUT (NO POWER)....9689
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)....9690
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)....9691
S-9 OIL BECOMES CONTAMINATED QUICKLY....9692
S-10 FUEL CONSUMPTION IS EXCESSIVE....9693
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN....9694
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)....9695
S-13 OIL LEVEL RISES....9696
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)....9697
S-15 ABNORMAL NOISE IS MADE....9698
S-16 VIBRATION IS EXCESSIVE....9699
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)....9700
TROUBLE DATA DISPLAY....9702
M-1 MAIN MONITOR DOES NOT WORK....9705
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP....9706
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY....9707
M-4 ABNORMALITY IN SHIFT INDICATOR....9708
(a) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F....9708
(b) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R....9708
(c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F....9708
(d) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS F WHEN DIRECTIONAL LEVER IS AT R ....9709
(e) DOES NOT DISPLAY 1ST, 4TH....9709
(f) DOES NOT DISPLAY 3RD, 4TH....9710
(g) DOES NOT DISPLAY 2ND, 3RD....9710
(h) DOES NOT DISPLAY 1ST, 2ND....9711
M-5 HIGH BEAM DOES NOT LIGHT UP....9712
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP....9713
(a) L.H. TURN SIGNAL DOES NOT LIGHT UP....9713
(b) R.H. TURN SIGNAL DOES NOT LIGHT UP....9713
M-7 ABNORMALITY IN PARKING DISPLAY....9714
(a) PARKING LAMP DOES NOT LIGHT UP....9714
(b) PARKING LAMP STAYS LIGHTED UP....9714
M-8 ABNORMALITY IN PREHEATING SYSTEM (QGS)....9715
(a) DOES NOT CARRY OUT PREHEATING ....9715
(b) ALWAYS CARRIES OUT PREHEATING FOR 1 MINUTE....9716
(c) PREHEATING STAYS ON ....9716
(d) PREHEATING TIME BECOMES SHORTER, OR THERE IS VARIATION....9717
M-9 NIGHT LIGHTING DOES NOT LIGHT UP....9718
M-10 ABNORMALITY IN FRONT WORKING LAMP....9719
(a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP....9719
(b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP....9719
(c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP....9719
M-11 ABNORMALITY IN REAR WORKING LAMP....9720
(a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP....9720
(b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP....9720
(c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP....9720
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF....9722
(a) WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN ....9722
(b) MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION STAYS ON ....9722
(c) MONITOR DISPLAY LIGHTS UP BUT CUT-OFF FUNCTION IS NOT ACTUATED....9723
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING ....9724
(a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N, AND CAUTION LAMP FLASHES....9724
(b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N....9724
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED ....9725
(a) ACTUATED CONTINUOUSLY....9725
(b) NOT ACTUATED....9725
M-15 ABNORMALITY IN BUZZER ....9726
(a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK)....9726
(b) BUZZER ALWAYS SOUNDS....9726
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY....9727
M-17 ABNORMALITY IN FAILURE DISPLAY MODE....9728
(a) DOES NOT ENTER FAILURE DISPLAY MODE ....9728
(b) TIMES FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE ....9728
M-18 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY....9729
(a) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP....9729
(b) EMERGENCY STEERING NORMAL DISPLAY STAYS LIGHTED UP....9729
M-19 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY....9730
(a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP....9730
(b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP....9730
M-20 ABNORMALITY IN AUTO-GREASING SYSTEM....9731
(a) FORCED GREASING CANNOT BE CARRIED OUT....9731
(b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)....9731
(c) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC)....9731
(d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC)....9732
(e) MONITOR DISPLAY GOES OUT ....9732
M-21 ABNORMALITY IN ECSS SYSTEM....9733
(a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED....9733
(b) MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK....9733
M-22 BUZZER DOES NOT SOUND WHEN AUTO-LEVELING SWITCH IS ACTUATED....9733
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)....9734
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)....9735
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOES NOT WORK....9736
(a) ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS....9736
(b) SOME LAMPS DO NOT LIGHT UP....9737
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT....9737
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), ALL LAMPS ON MAINTENANCE MONITOR DO NOT GO OUT....9738
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH....9739
(a) ENGINE OIL LEVEL DISPLAY FLASHES....9739
(b) ENGINE WATER LEVEL DISPLAY FLASHES ....9740
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH....9741
(a) ENGINE OIL PRESSURE DISPLAY FLASHES....9741
(b) BATTERY CHARGE LEVEL DISPLAY FLASHES....9742
(c) BRAKE OIL PRESSURE DISPLAY FLASHES....9743
(d) AIR CLEANER DISPLAY FLASHES....9744
K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND....9745
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS....9746
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT LIGHT UP....9747
(a) CHECK LAMP....9747
(b) CAUTION LAMP....9747
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHTS UP....9748
(a) CHECK LAMP....9748
(b) CAUTION LAMP....9748
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP)....9749
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP....9750
K-12 SERVICE METER DOES NOT WORK....9751
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED....9751
K-14 ABNORMALITY IN GAUGE ITEMS ....9752
(a) ABNORMALITY IN FUEL GAUGE....9752
(b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE....9753
(c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE....9754
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)....9755
E-1 ENGINE DOES NOT START ....9756
(a) STARTING MOTOR DOES NOT TURN ....9756
(b) STARTING MOTOR TURNS....9760
E-2 ENGINE DOES NOT STOP....9762
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING ....9762
E-4 PARKING BRAKE DOES NOT WORK ....9763
(a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON (PARKING)....9763
(b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE DROPS (DOES NOT WORK AS EMERGENCY BRAKE)....9763
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING ....9764
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON ....9766
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY)....9766
E-8 TRANSMISSION DOES NOT WORK NORMALLY ....9767
(a) PROBLEM IN COMMON CIRCUIT FOR TRANSMISSION (ALWAYS STAYS IN 2ND)....9769
(b) PROBLEM IN H-L CIRCUIT....9769
(c) PROBLEM IN SPEED CIRCUIT ....9770
(d) PROBLEM IN 4TH CIRCUIT (DOES NOT ENTER 4TH)....9770
(e) CONTACT IN H-L CIRCUIT....9771
(f) CONTACT IN SPEED CIRCUIT....9773
(g) CONTACT IN 4TH CIRCUIT (ALWAYS STAYS IN 4TH)....9775
(h) PROBLEM IN FORWARD CIRCUIT (REVERSE IS NORMAL)....9776
(i) PROBLEM IN REVERSE CIRCUIT (FORWARD IS NORMAL)....9778
(j) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE (DOES NOT TRAVEL FORWARD, PARKING BRAKE IS NORMAL)....9780
(k) CONTACT IN FORWARD CIRCUIT....9782
(l) CONTACT IN REVERSE CIRCUIT ....9784
(m) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE....9786
E-9 KICK-DOWN SWITCH DOES NOT WORK (THE REGULAR F1 TO F4 SHIFTS NORMALLY)....9787
E-10 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT HOLD IN POSITION (SELF-HOLDING FUNCTION))....9789
E-11 KICK-DOWN OPERATION CANNOT BE CANCELED ....9789
(a) NOT CANCELED EVEN WHEN DIRECTIONAL LEVER IS MOVED FROM F TO N OR R ....9789
(b) NOT CANCELED EVEN WHEN SPEED LEVER IS MOVED FROM 2ND TO OTHER POSITION (BECOMES 4TH)....9790
E-12 KICK-DOWN SWITCH IS ACTUATED BY MISTAKE WHEN TRAVELING IN 2ND ....9792
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED)(T MODE)....9793
POWER TRAIN ....9794
T-1 MACHINE DOES NOT START....9794
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES ....9796
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR....9798
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR....9799
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH....9800
STEERING SYSTEM....9801
T-6 STEERING DOES NOT TURN ....9801
T-7 STEERING WHEEL IS HEAVY....9802
T-8 STEERING WHEEL WOBBLES OR THERE IS EXCESSIVE SHOCK....9803
T-9 MACHINE STEERS TO ONE SIDE WHEN TRAVELING....9803
T-10 TURNING RADIUS TO LEFT AND RIGHT IS DIFFERENT....9803
BRAKE SYSTEM....9804
T-11 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR....9804
T-12 BRAKES ARE NOT RELEASED OR BRAKES DRAG....9805
T-13 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS....9806
WORK EQUIPMENT ....9807
T-14 BOOM DOES NOT RISE....9807
T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER....9808
T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT ....9809
T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)....9809
T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM....9809
T-19 BOOM SHAKES DURING OPERATION....9809
T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE....9810
T-21 BUCKET DOES NOT TILT BACK....9811
T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER....9812
T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION ....9813
T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER ....9813
T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET....9813
T-26 BUCKET SHAKES DURING LOADING OPERATION (MAIN CONTROL VALVE AT HOLD)....9814
T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT....9814
T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY ....9815
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)(D MODE)....9816
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM)....9817
D-1 ECSS DOES NOT WORK....9818
(a) ERROR CODE [d0] IS DISPLAYED ....9819
(b) ERROR CODE [d1] IS DISPLAYED ....9819
(c) ERROR CODE [d2] IS DISPLAYED ....9820
(d) ERROR CODE [d3] IS DISPLAYED ....9820
(e) ERROR CODE [d4] IS DISPLAYED ....9821
(f) NO ABNORMALITY DISPLAY IS GIVEN....9821
D-2 ECSS CANNOT BE CANCELED....9825
D-3 OUTPUT IS TURNED ON (TRAVEL SPEED DOES NOT BECOME 5 KM/H)(DEVIATES AROUND 5 KM/H)....9826
D-4 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 1ST ....9826
D-5 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 4TH....9827
D-6 CONTROLLER LED CODE IS NOT DISPLAYED ....9828
D-7 ECSS IS ABNORMAL BUT MAIN MONITOR DOES NOT GIVE ABNORMALITY DISPLAY....9828
TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (W MODE)....9829
OUTLINE....9831
1. FUNCTION....9831
2. WHEN CARRYING OUT TROUBLESHOOTING ....9831
3. FAILURE CODE TABLE....9831
4. TABEL OF TROUBLESHOOTING MODES AND CAUSES....9832
W-1 FAILURE CODE [40] ABNORMALITY IN BUCKET DUMP SOLENOID SYSTEM....9834
W-2 FAILURE CODE [41] SHORT CIRCUIT IN POWER SOURCE WHEN BUCKET DUMP, TILT SOLENOIDS ARE OFF....9835
W-3 FAILURE CODE [42] ABNORMALITY IN BUCKET TILT SOLENOID SYSTEM....9836
W-4 FAILURE CODE [43] ABNORMALITY IN DAMPING SOLENOID SYSTEM....9837
W-5 FAILURE CODE [44] SHORT CIRCUIT IN POWER SOURCE AT HOT END OF DAMPING SOLENOID ....9838
W-6 FAILURE CODE [45] SHORT CIRCUIT IN POWER SOURCE AT RETURN END OF DAMPING SOLENOID....9838
W-7 FAILURE CODE [48] ANMORMALITY IN BUCKET LEVER KICK-OUT RELAY SYSTEM....9839
W-8 FAILURE CODE [49] ABNORMALITY IN BOOM LEVER KICK-OUT RELAY SYSTEM....9841
W-9 FAILURE CODE [50] ABNORMALITY IN AUTO-LEVELER RELAY SYSTEM....9842
W-10 FAILURE CODE [51] DISCONNECTION IN BOOM RAISE, LOWER DETECTION PRESSURE SWITCH....9843
W-11 FAILURE CODE [52] ABNORMALITY IN BOOM ANGLE POTENTIONMETER SYSTEM....9844
W-12 FAILURE CODE [53] ABNORMALITY IN BUCKET ANGLE POTENTIOMETER SYSTEM....9844
W-13 FAILURE CODE [54] ABNORMALITY IN MODEL SELECTION WIRING HARNESS....9846
W-14 SENSOR CANNOT BE ADJUSTED....9847
W-15 DOES NOT CARRY OUT AUTO-LEVELING....9848
(a) AUTO-LEVELER SWITCH SYSTEM....9848
(b) AUTO-LEVELER LED SYSTEM....9848
(c) BUCKET LEVER NEUTRAL SWITCH SYSTEM....9849
(d) ENGINE SPEED SIGNAL SYSTEM....9850
W-16 AUTO-LEVELER CANNOT BE SET ....9851
(a) AUTO-LEVELER SET SWITCH SYSTEM....9851
(b) AUTO-LEVELER SET LED SYSTEM....9851
W-17 REMOTE POSITIONER RAISE, LOWER LEDS DO NOT LIGHT UP....9852
(a) REMOTE POSITIONER SWITCH SYSTEM....9852
(b) REMOTE POSITIONER LED SYSTEM....9852
W-18 REMOTE POSITIONER SET LEDS DO NOT FLASH....9853
(a) REMOTE POSITIONER SWITCH SYSTEM....9853
(b) REMOTE POSITIONER LED SYSTEM....9853
W-19 BUCKET DOES NOT TILT IMMEDIATELY AT BOOM FLOAT DETENT WHEN REMOTE POSITIONER IS AT RAISE AND AUTO MODE IS ON ....9854
W-20 BUZZER FOR SWITCH OPERATION DOES NOT SOUND....9855
W-21 BUCKET CORRECTION, BOOM STOP RESPONSE ARE SLOW....9856
W-22 BUCKET (LEVER) CONTROL ....9857
(a) BUCKET KICK-OUT DOES NOT WORK EVEN WHEN BUCKET IS AT MAXIMUM TILT ....9857
(b) LEVER IS NOT HELD BY DETENT ....9858
W-23 FAILURE CODE IS NOT DISPLAYED ON MAIN MONITOR....9860
W-24 MAINTENANCE MONITOR CHECK....9861
30 DISASSEMBLY AND ASSEMBLY....9862
METHOD OF USING MANUAL ....9864
PRECAUTIONS WHEN CARRYING OUT OPERATION ....9865
SPECIAL TOOL LIST....9867
STARTING MOTOR....9869
REMOVAL....9869
INSTALLATION....9869
ALTERNATOR....9870
REMOVAL ....9870
INSTALLATION....9870
ENGINE OIL COOLER....9871
REMOVAL....9871
INSTALLATION....9871
FUEL INJECTION PUMP....9872
REMOVAL....9872
INSTALLATION....9873
WATER PUMP....9874
REMOVAL....9874
INSTALLATION....9874
TURBOCHARGER....9875
REMOVAL....9875
INSTALLATION....9875
NOZZLE HOLDER ....9876
REMOVAL....9876
INSTALLATION....9876
THERMOSTAT....9877
REMOVAL ....9877
INSTALLATION....9877
CYLINDER HEAD....9878
REMOVAL....9878
INSTALLATION....9882
RADIATOR....9884
REMOVAL....9884
INSTALLATION....9886
ENGINE....9887
REMOVAL....9887
INSTALLATION....9892
TORQUE CONVERTER, TRANSMISSION ....9894
REMOVAL ....9894
INSTALLATION....9901
TORQUE CONVERTER....9903
DISASSEMBLY....9903
ASSEMBLY....9905
TRANSMISSION....9908
DISASSEMBLY....9908
ASSEMBLY....9913
TRANSMISSION CLUTCH PACK....9919
DISASSEMBLY....9919
ASSEMBLY....9928
PARKING BRAKE....9940
DISASSEMBLY....9940
ASSEMBLY....9942
TRANSMISSION CONTROL VALVE....9945
REMOVAL....9945
INSTALLATION....9947
DISASSEMBLY....9948
ASSEMBLY....9955
TRANSMISSION ACCUMULATOR VALVE....9963
DISASSEMBLY....9963
ASSEMBLY....9964
DRIVE SHAFT....9966
DISASSEMBLY....9966
ASSEMBLY....9968
FRONT AXLE....9970
REMOVAL....9970
INSTALLATION....9972
REAR AXLE ....9973
REMOVAL ....9973
INSTALLATION....9976
FRONT DIFFERENTIAL....9978
REMOVAL ....9978
INSTALLATION....9981
REAR DIFFERENTIAL....9983
REMOVAL....9983
INSTALLATION....9986
DIFFERENTIAL....9988
DISASSEMBLY....9988
ASSEMBLY....9991
FINAL DRIVE....9999
DISASSEMBLY....9999
ASSEMBLY....10002
CENTER HINGE PIN ....10006
REMOVAL....10006
INSTALLATION....10015
STEERING VALVE(ORBIT ROLL)....10021
REMOVAL....10021
INSTALLATION....10022
STEERING VALVE....10023
DISASSEMBLY....10023
ASSEMBLY....10026
REMOVAL....10031
INSTALLATION....10032
STEERING DEMAND VALVE....10033
DISASSEMBLY....10033
ASSEMBLY....10037
STEERING, SWITCH PUMP....10041
REMOVAL ....10041
INSTALLATION....10044
STEERING CYLINDER....10045
REMOVAL....10045
INSTALLATION....10046
BRAKE VALVE....10047
REMOVAL....10047
INSTALLATION....10048
RIGHT BRAKE VALVE (TANDEM)....10049
DISASSEMBLY....10049
ASSEMBLY....10050
LEFT BRAKE VALVE (SINGLE)....10051
DISASSEMBLY....10051
ASSEMBLY....10052
SLACK ADJUSTER....10053
REMOVAL....10053
INSTALLATION....10054
BRAKE....10057
DISASSEMBLY....10057
ASSEMBLY....10063
PARKING BRAKE DISC....10071
REMOVAL....10071
INSTALLATION....10073
ACCUMULATOR CHARGE VALVE....10074
REMOVAL....10074
INSTALLATION....10074
DISASSEMBLY....10075
ASSEMBLY....10077
HYDRAULIC TANK....10079
REMOVAL....10079
INSTALLATION....10081
WORK EQUIPMENT, PPC PUMP....10082
REMOVAL ....10082
INSTALLATION....10085
PPC VALVE....10086
REMOVAL....10086
INSTALLATION....10087
DISASSEMBLY....10088
ASSEMBLY....10089
MAIN CONTROL VALVE....10090
REMOVAL....10090
INSTALLATION....10092
DISASSEMBLY....10093
ASSEMBLY....10095
BUCKET CYLINDER....10097
REMOVAL....10097
INSTALLATION....10098
BOOM CYLINDER....10099
REMOVAL....10099
INSTALLATION....10100
HYDRAULIC CYLINDER....10101
DISASSEMBLY....10101
ASSEMBLY....10104
WORK EQUIPMENT ....10107
REMOVAL....10107
INSTALLATION....10110
COUNTERWEIGHT....10112
REMOVAL....10112
INSTALLATION....10112
FUEL TANK....10113
REMOVAL....10113
INSTALLATION....10114
CAB ....10115
REMOVAL ....10115
INSTALLATION....10116
MAIN MONITOR....10117
REMOVAL....10117
INSTALLATION....10118
MAINTENANCE MONITOR....10119
REMOVAL ....10119
INSTALLATION....10119
AIR CONDITIONER UNIT....10120
REMOVAL....10120
INSTALLATION....10123
AIR CONDITIONER CONDENSER....10126
REMOVAL ....10126
INSTALLATION....10127
DRY RECEIVER ....10128
REMOVAL....10128
INSTALLATION....10128
AIR CONDITIONER COMPRESSOR....10129
REMOVAL....10129
INSTALLATION....10130
40 MAINTENANCE STANDARD....10131
ENGINE MOUNT, TRANSMISSION MOUNT....10132
TORQUE CONVERTER....10133
TRANSMISSION....10134
TRANSMISSION CONTROL VALVE....10141
FLOW VALVE....10148
ACCUMULATOR VALVE....10149
DRIVE SHAFT....10151
DIFFERENTIAL....10152
FINAL DRIVE....10154
AXLE MOUNT....10155
STEERING COLUMN....10156
STEERING VALVE....10157
STEERING CYLINDER MOUNT....10158
SLACK ADJUSTER....10159
BRAKE VALVE....10160
BRAKE ....10163
PARKING BRAKE....10165
TORQUE CONVERTER, TRANSMISSION PUMP....10166
STEERING, SWITCH PUMP....10167
HYDRAULIC, PPC PUMP ....10168
PPC VALVE....10169
CUT-OFF VALVE....10170
MAIN CONTROL VALVE....10171
BOOM CYLINDER....10176
BUCKET CYLINDER....10177
CENTER HINGE PIN....10178
WORK EQUIPMENT LINKAGE....10180
BUCKET....10182
BUCKET POSITIONER AND BOOM KICK-OUT....10183
SEBMU4210106 - Wheel Loader WA470-1 Shop Manual....10184
COVER....10184
CONTENTS....10185
10 ENGINE....10203
12 TESTING AND ADJUSTING....10203
STANDARD VALUE TABLE....10204
TOOL LIST FOR TESTING AND ADJUSTING ....10206
ADJUSTING VALVE CLEARANCE....10207
MEASURING COMPRESSION PRESSURE....10208
TESTING AND ADJUSTING FUEL INJECTION TIMING....10209
MEASURING BLOW-BY PRESSURE....10211
TESTING AND ADJUSTING FAN BELT TENSION....10212
MEASURING EXHAUST GAS COLOR....10213
MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE....10214
TESTING AND ADJUSTING FUEL CUT SOLENOID....10218
13 DISASSEMBLY AND ASSEMBLY....10219
STARTING MOTOR ASSEMBLY....10220
REMOVAL....10220
INSTALLATION....10220
ALTERNATOR ASSEMBLY....10221
REMOVAL....10221
INSTALLATION....10221
FUEL INJECTION PUMP ASSEMBLY....10222
REMOVAL....10222
INSTALLATION....10222
WATER PUMP ASSEMBLY....10223
REMOVAL....10223
INSTALLATION....10223
NOZZLE HOLDER ASSEMBLY....10224
REMOVAL....10224
INSTALLATION....10225
TURBOCHARGER ASSEMBLY....10226
REMOVAL....10226
INSTALLATION....10226
CYLINDER HEAD ASSEMBLY....10227
REMOVAL....10227
INSTALLATION....10233
RADIATOR ASSEMBLY....10240
REMOVAL....10240
INSTALLATION....10243
OIL COOLER ASSEMBLY....10245
REMOVAL....10245
INSTALLATION....10245
ENGINE....10246
REMOVAL....10246
INSTALLATION....10252
FUEL TANK....10258
REMOVAL....10258
INSTALLATION....10258
14 MAINTENANCE STANDARD....10259
ENGINE MOUNT....10260
20 POWER TRAIN....10261
21 STRUCTURE AND FUNCTION....10261
GENERAL....10262
・HYDRAULIC CIRCUIT FOR POWER TRAIN....10264
・HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN....10265
DAMPER....10267
TORQUE CONVERTER AND TRANSMISSION PIPING....10269
TORQUE CONVERTER CHARGING PUMP....10270
TORQUE CONVERTER....10271
TORQUE CONVERTER OIL FILTER....10274
TORQUE CONVERTER OIL COOLER....10275
TORQUE CONVERTER RELIEF VALVE....10276
TRANSMISSION....10277
TRANSMISSION CONTROL VALVE....10285
UPPER VALVE....10289
LOWER VALVE....10290
TRANSMISSION SOLENOID VALVE....10293
EMERGENCY MANUAL SPOOL....10294
PRIORITY VALVE....10297
MODULATING VALVE AND QUICK RETURN VALVE....10298
ACCUMULATOR VALVE....10301
PILOT REDUCING VALVE....10303
TRANSMISSION PILOT FILTER....10304
TRANSFER....10305
DRIVE SHAFT....10306
AXLE MOUNT....10307
AXLE AND DIFFERENTIAL....10311
TORQUE PROPORTIONING DIFFERENTIAL....10316
FINAL DRIVE....10317
TIRE AND WHEEL....10319
22 TESTING AND ADJUSTING....10320
STANDARD VALUE TABLE....10321
TOOL LIST FOR TESTING AND ADJUSTING....10322
MEASURING ENGINE STALL SPEED....10323
MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION....10325
MEASURING SHIFT LEVER....10327
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL....10328
TIRE AND WHEEL....10330
TROUBLESHOOTING....10331
PRECAUTIONS WHEN TROUBLESHOOTING....10332
METHOD OF READING TROUBLESHOOTING TABLE....10334
PREVENTING RECURRENCE OF TROUBLE....10336
JUDGMENT ON POWER TRAIN....10337
TROUBLESHOOTING TABLE....10340
1. MACHINE DOES NOT MOVE....10340
2. MACHINE LACKS POWER OR SPEED....10342
3. EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR....10343
4. TORQUE CONVERTER OIL TEMPERATURE TOO HIGH....10344
23 DISASSEMBLY AND ASSEMBLY ....10345
DAMPER....10346
REMOVAL AND INSTALLATION (SERIAL NO.10001-19999)....10346
REMOVAL AND INSTALLATION (SERIAL NO.20001 AND UP)....10347
DISASSEMBLY (SERIAL NO.10001-19999)....10348
ASSEMBLY (SERIAL NO.10001-19999)....10350
DISASSEMBLY (SERIAL NO.20001 AND UP)....10352
ASSEMBLY (SERIAL NO.20001 AND UP)....10354
TORQUE CONVERTER CHARGING PUMP ....10358
REMOVAL AND INSTALLATION (SERIAL NO.10001-19999)....10358
REMOVAL (SERIAL NO.20001 AND UP)....10359
INSTALLATION (SERIAL NO.20001 AND UP)....10360
TORQUE CONVERTER AND TRANSMISSION....10361
REMOVAL (SERIAL NO.10001-19999)....10361
INSTALLATION (SERIAL NO.10001-19999)....10368
REMOVAL (SERIAL NO.20001 AND UP)....10376
INSTALLATION (SERIAL NO.20001 AND UP)....10384
TORQUE CONVERTER ASSEMBLY....10393
DISASSEMBLY....10393
ASSEMBLY....10397
TRANSMISSION ASSEMBLY....10403
DISASSEMBLY....10403
ASSEMBLY....10416
TRANSFER ASSEMBLY....10429
DISASSEMBLY....10429
ASSEMBLY....10432
TRANSMISSION CONTROL VALVE....10437
REMOVAL....10437
INSTALLATION....10440
DISASSEMBLY AND ASSEMBLY....10443
FRONT DIFFERENTIAL....10447
REMOVAL....10447
INSTALLATION....10451
REAR DIFFERENTIAL....10455
REMOVAL....10455
INSTALLATION....10459
DIFFERENTIAL....10463
DISASSEMBLY....10463
ASSEMBLY....10466
FRONT AXLE....10474
REMOVAL....10474
INSTALLATION....10477
REAR AXLE....10480
REMOVAL....10480
INSTILLATION....10485
DRIVE SHAFT....10490
DISASSEMBLY....10490
ASSEMBLY....10492
FINAL DRIVE....10494
DISASSEMBLY....10494
ASSEMBLY....10498
24 MAINTENANCE STANDARD....10503
TRANSMISSION MOUNT....10504
TORQUE CONVERTER CHARGING PUMP....10505
DAMPER....10506
TORQUE CONVERTER ....10509
TORQFLOW TRANSMISSION....10511
1. TRANSMISSION....10511
2. TRANSMISSION CONTROL VALVE....10514
3. SOLENOID VALVE....10522
TRANSFER....10523
DIFFERENTIAL....10525
FINAL DRIVE....10529
DRIVE SHAFT....10531
AXLE MOUNT....10532
40 STEERING SYSTEM....10534
41 STRUCTURE AND FUNCTION....10534
GENERAL....10535
HYDRAULIC CIRCUIT FOR STEERING....10537
STEERING VALVE (SERIAL NO.10001-20000)....10544
STEERING VALVE (SERIAL NO.20001 AND UP)....10551
TWO-WAY RESTRICTOR VALVE....10565
ORBIT-ROLL VALVE....10566
STOP VALVE....10570
STEERING PUMP....10571
STEERING CYLINDER....10572
STEERING COLUMN AND GEAR BOX....10573
STEERING LINKAGE....10574
STEERING COLUMN AND ORBIT-ROLL....10575
CENTER HINGE PIN....10576
42 TESTING AND ADJUSTING....10578
STANDARD VALUE TABLE....10579
TOOL LIST FOR TESTING AND ADJUSTING....10579
MEASURING STEERING WHEEL PLAY....10580
MEASURING OPERATING FORCE OF STEERING WHEEL ....10581
OPERATING TIME OF STEERING WHEEL....10582
TESTING STEERING LINKAGE....10583
ADJUSTING STEERING LINKAGE....10584
STEERING OIL PRESSURE....10585
TROUBLESHOOTING....10587
TROUBLESHOOTING TABLE (SERIAL NO.10001-20000)....10588
1. STEERING WHEEL DOES NOT TURN....10588
2. STEERING WHEEL IS SLUGGISH....10589
3. STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK....10590
4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING....10590
5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT....10590
TROUBLESHOOTING TABLE (SERIAL NO.20001 AND UP)....10591
1. STEERING WHEEL DOES NOT TURN....10591
2. STEERING WHEEL IS SLUGGISH....10592
3. STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK....10593
4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING....10593
5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT....10593
6. WHEN STEERING WHEEL IS TURNED FULLY TO LEFT OR RIGHT,CHASSIS IS SUBJECTED TO LARGE SHOCK....10593
43 DISASSEMBLY AND ASSEMBLY....10594
STEERING GEAR....10595
REMOVAL (SERIAL NO.10001-19999)....10595
INSTALLATION (SERIAL NO.10001-19999)....10596
DISASSEMBLY (SERIAL NO.10001-19999)....10597
ASSEMBLY (SERIAL NO.10001-19999)....10598
STEERING VALVE....10601
REMOVAL (SERIAL NO.20001 AND UP)....10601
INSTALLATION (SERIAL NO.20001 AND UP)....10603
DISASSEMBLY (SERIAL NO.20001 AND UP)....10606
ASSEMBLY (SERIAL NO.20001 AND UP)....10609
REMOVAL (SERIAL NO.10001-19999)....10614
INSTALLATION (SERIAL NO.10001-19999)....10616
DISASSEMBLY (SERIAL NO.10001-19999)....10618
ASSEMBLY (SERIAL NO.10001-19999)....10620
STEERING DEMAND VALVE....10622
REMOVAL (SERIAL NO.20001 AND UP)....10622
INSTALLATION (SERIAL NO.20001 AND UP)....10624
DISASSEMBLY (SERIAL NO.20001 AND UP)....10627
ASSEMBLY (SERIAL NO.20001 AND UP)....10631
STEERING PUMP....10635
REMOVAL (SERIAL NO.10001-19999)....10635
INSTALLATION (SERIAL NO.10001-19999)....10636
REMOVAL (SERIAL NO.20001 AND UP)....10637
INSTALLATION (SERIAL NO.20001 AND UP)....10638
STEERING CYLINDER ....10639
REMOVAL (SERIAL NO.10001-19999)....10639
INSTALLATION (SERIAL NO.10001-19999)....10640
REMOVAL (SERIAL NO.20001 AND UP)....10641
INSTALLATION (SERIAL NO.20001 AND UP)....10642
DISASSEMBLY....10643
ASSEMBLY....10645
CENTER HINGE PIN....10648
REMOVAL (SERIAL NO.10001-19999)....10648
INSTALLATION (SERIAL NO.10001-19999)....10655
REMOVAL (SERIAL NO.20001 AND UP)....10664
INSTALLATION (SERIAL NO.20001 AND UP)....10673
44 MAINTENANCE STANDARD....10684
STEERING LINKAGE....10685
STEERING COLUMN AND GEAR BOX....10687
STEERING COLUMN AND ORBIT-ROLL....10688
STEERING VALVE....10689
STEERING PUMP....10692
STEERING CYLINDER MOUNT....10693
STEERING CYLINDER ....10695
CENTER HINGE PIN....10696
50 BRAKE AND AIR SYSTEM....10698
51 STRUCTURE AND FUNCTION....10698
GENERAL....10699
BRAKE AND AIR PIPING....10700
BRAKE AND AIR CIRCUIT SYSTEM....10702
AIR TANK....10704
SAFETY VALVE....10706
BRAKE VALVE....10707
BRAKE ACTUATED....10708
OPERATING IN BALANCE....10709
BRAKE RELEASED....10710
AIR GOVERNOR....10711
TWO-WAY VALVE....10713
BRAKE CHAMBER....10714
SLACK ADJUSTER....10716
BRAKE....10719
PARKING BRAKE....10722
PARKING BRAKE SOLENOID VALVE....10724
SPRING CYLINDER....10725
BRAKE CALIPER....10726
52 TESTING AND ADJUSTING....10727
STANDARD VALUE TABLE....10728
TOOL LIST FOR TESTING AND ADJUSTING....10729
MEASURING BRAKE PEDAL....10730
MEASURING AIR....10731
BRAKE PERFORMANCE....10734
CHECKING BRAKE OIL PRESSURE....10735
MEASURING WEAR OF BRAKE DISC....10736
AIR BLEEDING FROM BRAKE LINE....10738
PARKING BRAKE PERFORMANCE....10739
CHECKING AND ADJUSTING PARKING BRAKE....10740
TROUBLESHOOTING....10742
TROUBLESHOOTING TABLE....10743
1. AIR PRESSURE DOES NOT RISES AT ALL....10743
2. AIR PRESSURE DOES NOT RISE TO THE SPECIFIED RANGE....10744
3. BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE....10745
4. BRAKE DOES NOT RELEASE,OR DRAGS....10746
5. PARKING BRAKE DOES NOT RELEASE,OR DRAGS....10747
53 DISASSEMBLY AND ASSEMBLY....10748
AIR GOVERNOR....10749
DISASSEMBL....10749
ASSEMBLY....10750
BRAKE VALVE....10751
REMOVAL (SERIAL NO.10001-19999)....10751
INSTALLATION (SERIAL NO.10001-19999)....10752
REMOVAL (SERIAL NO.20001 AND UP)....10753
INSTALLATION (SERIAL NO.20001 AND UP)....10754
DISASSEMBLY....10755
ASSEMBLY....10757
BRAKE CHAMBER....10759
REMOVAL (SERIAL NO.10001-19999)....10759
INSTALLATION (SERIAL NO.10001-19999)....10760
REMOVAL (SERIAL NO.20001 AND UP)....10761
INSTALLATION (SERIAL NO.20001 AND UP)....10763
DISASSEMBLY....10765
ASSEMBLY....10768
SLACK ADJUSTER....10771
REMOVAL AND INSTALLATION (SERIAL NO.10001-19999)....10771
REMOVAL (SERIAL NO.20001 AND UP)....10772
INSTALLATION (SERIAL NO.20001 AND UP)....10774
DISASSEMBLY....10776
ASSEMBLY....10777
BRAKE ASSEMBLY....10778
DISASSEMBLY....10778
ASSEMBLY....10784
DISASSEMBLY (SERIAL NO.20001 AND UP)....10791
ASSEMBLY (SERIAL NO.20001 AND UP)....10797
SPRING CYLINDER ....10805
REMOVAL ....10805
INSTALLATION....10806
DISASSEMBLY....10807
ASSEMBLY....10809
PARKING BRAKE....10811
REMOVAL....10811
INSTALLATION....10813
PARKING BRAKE PAD....10816
REMOVAL AND INSTALLATION ....10816
54 MAINTENANCE STANDARD....10817
BRAKE VALVE....10818
BRAKE CHAMBER....10820
SLACK ADJUSTER....10821
BRAKE....10822
PARKING BRAKE....10826
SPRING CYLINDER....10827
60 WORK EQUIPMENT SYSTEM....10828
61 STRUCTURE AND FUNCTION....10828
GENERAL ....10829
HYDRAULIC PIPING....10830
HYDRAULIC CIRCUIT SYSTEM....10832
HYDRAULIC CIRCUIT DIAGRAM....10833
HYDRAULIC TANK....10837
OIL FILTER BYPASS VALVE....10839
HYDRAULIC PUMPS....10841
HYDRAULIC PUMP ....10841
SWITCH AND POC (PPC) PUMP....10842
POC VALVE....10843
PPC VALVE....10845
POC (PPC) RELIEF VALVE....10847
FUNCTION OF POC VALVE....10848
FUNCTION OF PPC VALVE....10853
MAIN CONTROL VALVE....10855
RELIEF VALVE....10863
SAFETY VALVE (WITH SUCTION VALVE)....10864
SUCTION VALVE....10865
FLOAT SELECTOR VALVE AND UNLOADER VALVE....10866
ACCUMULATOR....10874
HYDRAULIC CYLINDER....10875
BUCKET LINKAGE....10877
BUCKET POSITIONER AND BOOM KICK-OUT....10879
WORK EQUIPMENT LEVER LINKAGE....10882
62 TESTING AND ADJUSTING....10884
STANDARD VALUE TABLE....10885
TOOL LIST FOR TESTING AND ADJUSTING....10888
MEASURING DUMP AND LIFT CONTROL LEVERS....10889
ADJUSTING DUMP AND LIFT CONTROL LEVERS....10890
MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT....10892
MEASURING WORK EQUIPMENT....10895
MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT....10896
ADJUSTING BUCKET POSITIONER....10897
ADJUSTING BOOM KICK-OUT....10898
TROUBLESHOOTING....10899
TROUBLESHOOTING TABLE....10900
1. LIFT ARM DOES NOT RISE....10900
2. LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER....10901
3. LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT....10902
4. RUCKET CANNOT BE HELD DOWN WITH LIFT CYLINDER....10902
5. LIFT ARM HAS LARGE HYDRAULIC DRIFT....10902
6. LIFT ARM MOVEMENT IS UNSTEADY DURING WORK....10902
7. LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "RAISE"....10902
8. BUCKET DOES NOT TILT BACK....10903
9. BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER....10904
10. BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK....10905
11. BUCKET CANNOT BE HELD DOWN BY THE BUCKET CYLINDER....10905
12. BUCKET HAS LARGE HYDRAULIC DRIFT....10905
13. BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVELS UNDER LOAD (MAIN CONTROL VALVE IN "HOLD")....10905
14. BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "TILT BACK"....10905
15. CONTROL LEVERS OF LIFT ARM AND DUMP MOVE STIFFLY AND SLUGGISHLY....10906
63 DISASSEMBLY AND ASSEMBLY....10907
HYDRAULIC TANK....10908
REMOVAL (SERIAL NO.10001-19999)....10908
INSTALLATION (SERIAL NO.10001-19999)....10909
REMOVAL (SERIAL NO.20001 AND UP)....10910
INSTALLATION (SERIAL NO.20001 AND UP)....10914
HYDRAULIC PUMP....10917
REMOVAL (SERIAL NO.10001-19999)....10917
INSTALLATION (SERIAL NO.10001-19999)....10918
REMOVAL (SERIAL NO.20001 AND UP)....10919
INSTALLATION (SERIAL NO.20001 AND UP)....10920
HYDRAULIC FILTER....10921
REMOVAL AND INSTALLATION....10921
SWITCH,POC PUMP....10922
REMOVAL AND INSTALLATION (SERIAL NO.10001-19999)....10922
SWITCH,PPC PUMP....10923
REMOVAL (SERIAL NO.20001 AND UP)....10923
INSTALLATION (SERIAL NO.20001 AND UP)....10924
POC VALVE....10925
REMOVAL (SERIAL NO.10001-19999)....10925
INSTALLATION (SERIAL NO.10001-19999)....10927
DISASSEMBLY AND ASSEMBLY (SERIAL NO.10001-19999)....10929
PPC VALVE....10930
REMOVAL (SERIAL NO.20001 AND UP)....10930
INSTALLATION (SERIAL NO.20001 AND UP)....10932
DISASSEMBLY AND ASSEMBLY (SERIAL NO.20001 AND UP)....10934
MAIN CONTROL VALVE....10935
REMOVAL (SERIAL NO.10001-19999)....10935
INSTALLATION (SERIAL NO.10001-19999)....10937
DISASSEMBLY (SERIAL NO.10001-19999)....10939
ASSEMBLY (SERIAL NO.10001-19999)....10941
REMOVAL (SERIAL NO.20001 AND UP)....10943
INSTALLATION (SERIAL NO.20001 AND UP)....10946
DISASSEMBLY (SERIAL NO.20001 AND UP)....10948
ASSEMBLY (SERIAL NO.20001 AND UP)....10950
DUMP CYLINDER....10952
REMOVAL....10952
INSTALLATION....10954
LIFT CYLINDER....10956
REMOVAL....10956
INSTALLATION....10957
LIFT AND DUMP CYLINDERS....10958
DISASSEMBLY....10958
ASSEMBLY....10960
WORK EQUIPMENT....10963
REMOVAL....10963
INSTALLATION....10966
COUNTERWEIGHT....10969
REMOVAL AND INSTALLATION....10969
64 MAINTENANCE STANDARD....10970
MAIN CONTROL VALVE....10971
SWITCH AND POC (PPC) PUMP....10979
HYDRAULIC PUMP....10981
POC VALVE....10982
POC VALVE (RELIEF VALVE)....10983
PPC VALVE....10984
DUMP CYLINDER....10986
LIFT CYLINDER....10987
BUCKET LINKAGE....10988
BUCKET POSITIONER AND BOOM KICK-OUT....10990
BUCKET....10991
80 ELECTRIC AND ELECTRONIC SYSTEM....10992
81 STRUCTURE AND FUNCTION....10992
ELECTRICAL WIRING DIAGRAM....10993
ELECTRICAL WIRING DIAGRAM CIRCUIT....10994
ENGINE STARTING CIRCUIT....11001
ENGINE STOP CIRCUIT....11004
PREHEATING CIRCUIT....11007
PREHEATING AND AFTER-HEATING WITH HEATER SWITCH....11007
PREHEATING WITH STARTING SWITCH....11008
AUTOMATIC PREHEATING....11009
COMBINATION SWITCH....11010
ELECTRICAL TRANSMISSION CONTROL....11011
TRANSMISSION CUT-OFF SWITCH....11013
TRANSMISSION CUT-OFF SELECTOR SWITCH....11014
NEUTRALIZER RELAY....11016
KICK-DOWN SWITCH....11018
KICK-DOWN ELECTRIC CIRCUIT....11019
ELECTRICAL PARKING BRAKE CONTROL ....11025
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)....11037
INDICATION ON MONITOR PANEL....11041
CONTROLLER....11043
SENSORS....11044
WIRING HARNESS....11050
OPERATION OF PROXIMITY SWITCH....11052
82 TESTING AND ADJUSTING....11056
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM....11057
ADJUSTING MACHINE MONITOR (SPEEDOMETER MODULE)....11059
TROUBLESHOOTING....11061
CHECKS BEFORE TROUBLESHOOTING....11062
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART....11063
CONNECTOR TERMINAL NUMBERS....11065
PRECAUTION WHEN HANDLING CONNECTOR....11070
ELECTRICAL WIRING DIAGRAM....11072
ELECTRICAL CIRCUIT SYSTEM....11074
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (SERIAL NO.10001-20000)....11084
E-1. ENGINE DOES NOT START....11085
E-1A. ENGINE DOES NOT START....11087
E-2. ENGINE DOES NOT STOP....11089
E-3. ENGINE STOPS WHEN TRAVELING....11091
E-4. PARKING BRAKE DOES NOT WORK....11093
E-5. PARKING BRAKE IS APPLIED WHEN TRAVELING....11095
E-6. PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED TO ON ....11097
E-7. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED....11098
E-8. MACHINE DOES NOT TRAVEL FORWARD....11099
E-9. MACHINE DOES NOT TRAVEL REVERSE....11101
E-10. TRANSMISSION DOES NOT SHIFT GEAR (F-R SWITCH NORMAL)....11103
E-11. MACHINE DOES NOT TRAVEL WHEN TRANSMISSION CUT-OFF SELECTOR SWITCH IS ON (MACHINE TRAVELS ONLY WHEN TRANSMISSION CUT-OFF SELECTOR SWITCH IS OFF)....11105
E-12. TRANSMISSION CANNOT BE CUT-OFF....11106
E-13. TRANSMISSION DOES NOT RETURN TO NEUTRAL....11107
E-14. PREHEATING DISPLAY DOES NOT GO OUT....11109
E-15. PREHEATING DOES NOT WORK....11110
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (SERIAL NO.20001 AND UP)....11111
POSITION OF CONNECTORS FOR TROUBLESHOOTING....11112
E-1. ENGINE DOES NOT START....11118
E-2. ENGINE DOES NOT STOP....11122
E-3. ENGINE STOPS WHEN TRAVELING....11122
E-4. PARKING BRAKE DOES NOT WORK....11123
E-5. PARKING BRAKE IS APPLIED WHEN TRAVELING....11124
E-6. PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON ....11126
E-7. WHEN PARKING BRAKE IS APPLIED,SHIFT LEVER DOES NOT ENTER NEUTRAL....11126
E-8. TRANSMISSION DOES NOT WORK NORMALLY....11127
E-9. KICK-DOWN SWITCH DOES NOT WORK (NORMAL F1-F4 SWITCHES CORRECTLY)....11147
E-10. KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT CARRY OUT SELF-HOLD OPERATION)....11150
E-11. KICK-DOWN OPERATION IS NOT CANCELED....11151
E-12. KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2....11153
E-13. MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED....11153
E-14. PREHEAT DISPLAY STAYS ON....11155
E-15. PREHEATING DOES NOT STOP....11155
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM [SERIAL NO.10001-10080 (M SPEC.), SERIAL NO.10001-10118 (P SPEC.), SERIAL NO.10001-10125 (D SPEC.) ....11156
M-1. WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE),AND THERE IS NO ABNORMALITY IN MACHINE,CHECK BEFORE STARTING ITEM FLASHES....11159
a) BRAKE OIL LEVEL....11159
b) ENGINE OIL LEVEL....11160
c) COOLANT LEVEL....11161
M-2. WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED),CAUTION ITEMS FLASHES....11162
a) BATTERY CHARGE....11162
b) FUEL LEVEL....11163
M-3. WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED),EMERGENCY ITEMS FLASHES....11164
a) FAILURE IN BRAKE LINE....11164
b) ENGINE OIL PRESSURE....11165
c) COOLANT LEVEL....11166
d) DROP IN AIR PRESSURE....11167
e) COOLANT TEMPERATURE....11168
f) TORQUE CONVERTER OIL TEMPERATURE....11169
M-4. WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE),PILOT ITEMS LIGHT UP ABNORMALLY,OR DOES NOT LIGHT UP....11170
a) PARKING BRAKE DISPLAY DOES NOT GO OUT....11170
b) PARKING BRAKE DISPLAY DOES NOT LIGHT UP....11171
c) WORKING LAMP DISPLAY DOES NOT GO OUT....11172
d) WORKING LAMP DISPLAY DOES NOT LIGHT UP....11173
e) PREHEAT DISPLAY LIGHTS UP....11174
f) PREHEAT DISPLAY DOES NOT LIGHT UP....11175
g) FAILURE IN MAIN STEERING DISPLAY LIGHT UP (IF EQUIPPED)....11176
h) FAILURE IN MAIN STEERING DISPLAY DOES NOT LIGHT UP (IF EQUIPPED)....11177
i) EMERGENCY STEERING NORMAL DISPLAY LIGHTS UP (IF EQUIPPED)....11178
j) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP (IF EQUIPPED)....11179
k) TRANSMISSION CUT-OFF DISPLAY LIGHTS UP....11180
l) TRANSMISSION CUT-OFF DISPLAY DOES NOT LIGHT UP....11181
M-5. TURN SIGNAL LAMPS,HIGH BEAM LIGHT UP ABNORMALLY,OR DO NOT LIGHT UP....11182
a) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) LIGHTS UP....11182
b) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) LIGHTS UP....11182
c) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP....11183
d) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP....11184
e) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP....11185
f) HIGE BEAM PILOT LAMP DOES NOT WORK NORMALLY....11186
M-6. SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY....11187
M-7. SERVICEMETER DOES NOT WORK NORMALLY....11188
M-8. ABNORMALITY IN MONITOR PANEL....11190
a) NONE OF MONITOR PANEL WORKS....11190
b) PART OF MONITOR PANEL DOES NOT WORK....11192
c) EVEN WHEN ENGINE IS STOPPED,ENGINE OIL PRESSURE FLASHES,CAUTION BUZZER SOUNDS AND WARNING LAMP ALSO LIGHTS UP....11193
d) EVEN WHEN ENGINE IS STOPPED,BATTERY CHARGE FLASHES AND WARNING LAMP LIGHTS UP ....11194
e) NO LAMPS ON MONITOR LIGHTS UP (IMMEDIATELY AFTER TURNING STARTING SWITCH TO "ON",ENGINE STOPPED)....11194
f) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING LAMP LIGHTS UP INTERMITTENTLY....11195
g) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY....11196
h) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY....11197
i) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY....11198
M-9. ABNORMALITY IN PANEL LAMPS ON MONITOR....11199
a) NO PANEL LAMPS LIGHT UP EVEN WHEN ONLY SMALL LAMP IN COMBINATION LAMP IS USED....11199
b) NO PANEL LAMPS LIGHT UP EVEN WORKING LAMP IS SWITCHED ON....11201
c) PANEL LAMPS OF GAUGE MODULE DO NOT LIGHT UP....11202
d) PANEL LAMPS OF CHECKS,CAUTION 1 AND 2,SPEEDOMETER MODULE DO NOT LIGHT UP....11203
e) PANEL LAMPS OF SERVICE METER DO NOT LIGHT UP....11204
M-10. ABNORMALITY IN ALARM BUZZER OR WARNING LAMP....11205
a) EMERGENCY ITEM IS FLASHING,BUT ALARM BUZZER DOES NOT SOUND....11205
b) EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING,BUT WARNING LAMPS DOES NOT FLASH....11207
M-11. ABNORMALITY IN GAUGE....11209
a) FUEL GAUGE....11209
b) AIR PRESSURE GAUGE....11212
c) COOLANT TEMPERATURE GAUGE....11214
d) TORQUE CONVERTER OIL TEMPERATURE GAUGE....11216
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM [SERIAL NO.10081 AND UP (M SPEC.), SERIAL NO.10119 AND UP (P SPEC.), SERIAL NO.10126 AND UP (D SPEC.)]....11218
POSITION OF CONNECTORS FOR TROUBLESHOOTING....11220
SERIAL NO.10081-20000 (M SPEC.)....11220
SERIAL NO.10119-20000 (P SPEC.)....11220
SERIAL NO.10126-20000 (D SPEC.)....11220
(SERIAL NO.20001 AND UP)....11226
M-1. WHEN STARTING SWITCH IS TURNED TO ON POSITION,MONITOR PANEL DOES NOT LIGHT UP FOR 3 SECONDS....11232
a) NONE OF MONITOR PANEL LIGHTS UP....11232
b) EXCEPT FOR SPEEDOMETER MODULE,NONE OF MONITOR PANEL LIGHTS UP....11232
c) NONE OF CAUTION ITEMS LIGHT UP....11232
d) SOME OTHER PARTS DO NOT LIGHT UP....11232
M-2. WHEN STARTING SWITCH IS TURNED TO ON POSITION,ALL MONITOR PANEL LIGHTS UP AND DOES NOT GO OUT....11233
M-3. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED),CHECK ITEM FLASHES (LEVELS OF CHECK ITEMS ARE CORRECT)....11234
a) (ENGINE OIL LEVEL) FLASHES....11234
b) (RADIATOR WATER LEVEL) FLASHES....11235
c) (BRAKE OIL LEVEL) FLASHES....11235
M-4. NO OPERATION IS BEING CARRIED OUT,BUT PILOT DISPLAY LIGHTS UP ABNORMALLY....11237
a) (PREHEAT) LIGHT UP....11237
b) (TRANSMISSION CUT-OFF) LIGHTS UP....11237
c) (PARKING BRAKE) LIGHTS UP....11238
d) (WORKING LAMP) LIGHTS UP....11238
M-5. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED),CHECK ITEM FLASHES....11240
a) ENGINE OIL PRESSURE SYSTEM....11240
b) ALTERNATOR SYSTEM....11240
M-6. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED),CAUTION ITEM FLASHES....11241
a) ENGINE OIL PRESSURE SYSTEM....11241
b) ALTERNATOR SYSTEM....11241
M-7. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED),CAUTION ITEM FLASHES. (FLASHING ITEMS ARE SPECIFIED VALUE)....11243
a) (CHARGE LEVEL) FLASHES....11243
b) (FUEL LEVEL) FLASHES....11243
c) (BRAKE LINE FAILURE) FLASHES....11243
d) (ENGINE OIL PRESSURE) FLASHES....11243
e) (RADIATOR WATER LEVEL) FLASHES....11243
f) (AIR PRESSURE) FLASHES....11244
g) (ENGINE WATER TEMPERATURE) FLASHES....11244
h) (TORQUE CONVERTER OIL TEMPERATURE) FLASHES....11244
M-8. SPEED SENSOR DISPLAY STAYS AT "O"....11246
M-9. HIGH BEAM DOES NOT LIGHT UP,OR LIGHTS UP ABNORMALLY....11247
a) IF HIGH BEAM DOES NOT LIGHT UP....11247
b) IF HIGH BEAM LIGHTS UP WHEN HEAD LAMP SWITCH IS OFF....11247
c) IF HI BEAM DISPLAY LIGHTS UP WHEN HEAD LAMP DIMMER SWITCH IS AT LO BEAM POSITION....11248
M-10. TURN SIGNAL LAMP DOES NOT FLASH. TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING....11249
a) IF TURN SIGNAL LAMP DOES NOT FLASH....11249
b) IF TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING....11249
M-11. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED),BUZZER DOES NOT SOUND FOR 1 SEC. CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND....11250
M-12. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY,BUT ALARM BUZZER SOUNDS....11251
M-13. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED),WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. CAUTION ITEM IS FLASHING BUT WARNING LAMP DOES NOT FLASH....11252
M-14. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY,BUT WARNING LAMP LIGHTS UP....11252
M-15. WHEN STARTING SWITCH IS TURNED TO ON POSITION,LAMPS DO NOT LIGHT UP FOR 4 SEC.WHEN LAMP SWITCH IS ON,LAMPS DO NOT LIGHT UP....11253
a) NONE OF PANEL LIGHTS UP....11253
b) SOME OF PANEL LAMPS DO NOT LIGHT UP....11253
M-16. LAMP SWITCH IS NOT BEING OPERATED,BUT NIGHT LIGHTING LIGHTS UP.NIGHT LIGHTING STAYS ON....11254
M-17. SERVICE METER DOES NOT WORK....11255
M-18. SERVICE METER MOVES WHEN ENGINE IS STOPPED....11255
M-19. ABNORMALITY IN AIR PRESSURE GAUGE....11256
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA....11256
b) IF INDICATOR REMAINS AT MAXIMUM LEVEL....11256
M-20. ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE....11257
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA....11257
b) IF INDICATOR REMAINS AT MINIMUM LEVEL....11257
M-21. ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGA....11258
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA....11258
b) IF INDICATOR REMAINS AT MINIMUM LEVEL....11258
M-22. ABNORMALITY IN FUEL GAUGE....11259
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA....11259
b) IF INDICATOR REMAINS AT FULL....11259
83 DISASSEMBLY AND ASSEMBLY....11260
MACHINE MONITOR....11261
REMOVAL AND INSTALLATION....11261
90 OTHERS....11262
91 LOGGING SPECIFICATIONS....11262
HYDRAULIC CIRCUIT DIAGRAM....11263
MAIN CONTROL VALVE....11264
ARM CYLINDER....11266
WORK EQUIPMENT....11267
DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY....11268
ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY....11270
MAIN CONTROL VALVE....11272
WORK EQUIPMENT....11274
ARM CYLINDER....11276
93 DISASSEMBLY AND ASSEMBLY....11277
CAB....11278
REMOVAL....11278
INSTALLATION....11278
97 GEAR PUMP....11279
GENERAL....11279
GENERAL....11280
PRINCIPLE OF OPERATION....11281
PRESSURE LOADED TYPE GEAR PUMP....11284
FIXED SIDE PLATE TYPE GEAR PUMP....11286
SA SERIES....11287
STRUCTURE....11288
TESTING AND ADJUSTING....11291
DISASSEMBLY....11294
ASSEMBLY....11298
MAINTENANCE STANDARD....11303
SEN06006-02 - Wheel Loader WA470-7 Shop Manual....11304
Cover....11304
00 Index and foreword ....11306
Index ....11307
Foreword, safety and general information ....11323
Important safety notice ....11323
How to read the shop manual ....11330
Explanation of terms for maintenance standard ....11332
Handling equipment of fuel system devices ....11334
Handling of intake system parts ....11335
Handling of hydraulic equipment ....11336
Method of disconnecting and connecting of push-pull type coupler ....11338
Handling of electrical equipment ....11341
How to read electric wire code ....11349
Precautions when performing operation ....11352
Practical use of KOMTRAX ....11356
Standard tightening torque table ....11357
List of abbreviation ....11361
Conversion table ....11366
01 Specification ....11372
Table of contents ....11373
Specifications ....11374
Specification drawing ....11374
Specifications ....11376
Weight table ....11382
Table of fuel, coolant, and lubricants ....11384
10 Structure and function ....11386
Table of contents ....11387
Engine and cooling system ....11389
Engine related parts ....11389
KVGT ....11391
EGR system piping drawing ....11397
EGR system circuit diagram ....11399
EGR valve ....11400
EGR cooler ....11402
KCCV layout drawing ....11404
KCCV ventilator ....11406
KDPF ....11408
Cooling system ....11412
Cooling fan pump ....11415
Cooling fan motor ....11424
Power train ....11431
Power train system ....11431
Drive shaft ....11434
Power train piping drawing ....11435
Transmission control ....11436
Torque converter ....11439
Transmission ....11444
Transmission control valve ....11463
Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV ....11466
3rd, 4th clutch ECMV ....11473
Lockup clutch ECMV ....11480
Main relief and torque converter relief valve ....11484
Axle ....11486
Differential ....11488
Final drive ....11498
Steering system ....11500
Layout of steering parts ....11500
Steering column ....11501
Steering pump ....11502
Steering valve ....11514
Orbit-roll valve ....11528
Stop valve ....11534
Emergency steering motor ....11535
Emergency steering pump ....11536
Brake system ....11537
Layout of brake parts ....11537
Charge valve ....11539
Brake valve ....11545
Slack adjuster ....11549
Accumulator (for brake) ....11552
Brake ....11553
Parking brake control ....11556
Parking brake ....11557
Parking brake solenoid valve ....11558
Parking brake emergency release valve ....11561
Undercarriage and frame ....11562
Axle mount and center hinge pin ....11562
Tire ....11563
Hydraulic system ....11565
Hydraulic component layout ....11565
Work equipment control ....11567
Hydraulic tank ....11568
Double type gear pump ....11571
Work equipment pump ....11572
Control valve ....11593
CLSS ....11602
Hydraulic circuit diagram and names of valves ....11606
Accumulator charge valve ....11617
Work equipment lock solenoid valve ....11621
Accumulator (for PPC circuit) ....11622
Accumulator (for ECSS) ....11623
Work equipment ....11624
Work equipment linkage ....11624
Bucket ....11625
Bucket positioner and boom positioner ....11626
Cab and its attachments ....11627
ROPS cab ....11627
Electrical system ....11628
Engine control system ....11628
Preheating system ....11630
Engine power mode selector circuit ....11632
Engine output limit function ....11633
Automatic warm-up function ....11634
Parking brake control system ....11635
System operating lamp function ....11637
Battery disconnect switch function ....11639
Transmission controller system ....11641
Work equipment control system ....11662
Machine monitor system ....11678
Rear view monitor system ....11702
KOMTRAX system ....11705
System component parts ....11708
Sensor ....11735
20 Standard value tables ....11764
Table of contents ....11765
Standard service value table ....11766
Standard value table for engine ....11766
Standard value table for machine ....11768
Standard value table for electrical system ....11781
30 Testing and adjusting ....11796
Table of contents ....11797
General information on testing and adjusting ....11799
Tools for testing and adjusting ....11799
Sketch of tools for testing and adjusting ....11803
Engine and cooling system ....11805
Testing engine speed ....11805
Testing boost pressure ....11807
Testing exhaust gas color ....11809
Testing and adjusting valve clearance ....11811
Testing compression pressure ....11813
Testing blowby pressure ....11817
Testing engine oil pressure ....11819
Testing EGR valve and KVGT oil pressures ....11820
Testing fuel pressure ....11821
Testing fuel return rate and leakage ....11822
Bleeding air from fuel system ....11826
Testing fuel circuit for leakage ....11828
Handling cylinder cutout mode operation ....11829
Handling no injection cranking operation ....11830
Testing of KDPF and muffler stack for looseness and damage ....11831
Testing of installed condition of cylinder head and manifolds ....11832
Testing engine piping for damage and looseness ....11833
Testing and adjusting air conditioner compressor belt tension ....11834
Testing and adjusting alternator belt tension ....11836
Procedures for cleaning fuel doser ....11838
Writing compensation values at replacement of injector and engine controller ....11841
Power train ....11845
Adjusting transmission output speed sensor ....11845
Adjusting transmission input speed sensor ....11846
Flushing procedure for torque converter and transmission hydraulic circuit ....11847
Retrieval of disabled machine due to transmission valve failure ....11849
Testing oil leakage from axle final drive ....11851
Testing drive shaft for looseness, backlash, and damage ....11852
Testing and adjusting power train oil pressure ....11853
Steering system ....11868
Testing directional lever ....11868
Testing steering wheel ....11869
Testing work equipment control lever ....11871
Testing and adjusting steering circuit oil pressure ....11873
Bleeding air from steering cylinder circuit. ....11876
Testing and adjusting steering stopper valve ....11877
Brake system ....11878
Testing brake pedal ....11878
Testing and adjusting brake pedal linkage ....11879
Testing braking performance ....11880
Testing and adjusting of accumulator charge pressure ....11881
Testing of brake accumulator nitrogen gas pressure and procedure for charging brake accumulator with nitrogen gas ....11883
Testing wheel brake oil pressure ....11887
Testing lowering of wheel brake pressure ....11889
Testing wear of wheel brake disc ....11891
Bleeding air from wheel brake circuit ....11892
Releasing remaining pressure in brake accumulator circuit ....11894
Testing parking brake performance ....11895
Testing parking brake oil pressure ....11896
Testing wear of parking brake disc ....11897
Method of releasing parking brake manually ....11898
Hydraulic system ....11900
Testing fan speed ....11900
Testing fan pump circuit oil pressure ....11901
Bleeding air from hydraulic fan circuit ....11903
Testing and adjusting work equipment EPC oil pressure ....11905
Testing and adjusting work equipment oil pressure ....11908
Bleeding air from work equipment circuit ....11912
Releasing remaining pressure from work equipment circuit ....11913
Testing of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ....11914
Work equipment ....11918
Testing and adjusting bucket position detection lever ....11918
Testing and adjusting boom position detection lever ....11919
Electrical system ....11920
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ....11920
Special functions of machine monitor ....11922
Adjusting rearview camera angle ....12011
Handling voltage circuit of engine controller ....12012
Handling battery disconnect switch ....12013
Testing diodes ....12014
Pm clinic ....12015
Pm Clinic service ....12015
Check sheet ....12016
40 Troubleshooting ....12022
Table of contents ....12023
General information on troubleshooting ....12032
Troubleshooting points ....12032
Sequence of events in troubleshooting ....12034
Check before troubleshooting ....12036
Inspection procedure before troubleshooting ....12038
Preparation work for troubleshooting of electrical system ....12055
Classification and procedures for troubleshooting ....12061
Symptom and troubleshooting numbers ....12064
Information in troubleshooting table ....12067
Connector list and layout ....12069
Connector contact identification ....12083
T-branch box and T-branch adapter table ....12119
Fuse location table ....12125
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ....12128
Precautions on troubleshooting of machine monitor ....12131
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ....12133
Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors) ....12138
Fabrication of short-circuit connector (for CA1883 and CA3135) ....12139
Failure codes table ....12140
Troubleshooting by failure code (Display of code) ....12154
Failure code [1500L0] Double Engagement of T/M Clutches ....12154
Failure code [15SAL1] Release Trouble of ECMV (Forward) ....12155
Failure code [15SALH] Malfunction of ECMV (Forward) ....12157
Failure code [15SBL1] Release Trouble of ECMV (Reverse) ....12159
Failure code [15SBLH] Malfunction of ECMV (Reverse) ....12161
Failure code [15SEL1] Release Trouble of ECMV (1st) ....12163
Failure code [15SELH] Malfunction of ECMV (1st) ....12165
Failure code [15SFL1] Release Trouble of ECMV (2nd) ....12167
Failure code [15SFLH] Malfunction of ECMV (2nd) ....12169
Failure code [15SGL1] Release Trouble of ECMV (3rd) ....12171
Failure code [15SGLH] Malfunction of ECMV (3rd) ....12173
Failure code [15SHL1] Release Trouble of ECMV (4th) ....12175
Failure code [15SHLH] Malfunction of ECMV (4th) ....12177
Failure code [2F00MA] Failure of Parking Brake Circuit ....12179
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ....12183
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ....12185
Failure code [879AKA] A/C Inner Sensor Open Circuit ....12187
Failure code [879AKB] A/C Inner Sensor Short Circuit ....12188
Failure code [879BKA] A/C Outer Sensor Open Circuit ....12189
Failure code [879BKB] A/C Outer Sensor Short Circuit ....12190
Failure code [879CKA] Ventilating Sensor Open Circuit ....12191
Failure code [879CKB] Ventilating Sensor Short Circuit ....12192
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ....12193
Failure code [879EMC] Ventilation Damper Abnormality ....12194
Failure code [879FMC] Air Mix Damper Abnormality ....12195
Failure code [989A00] Engine Overrun Prevention Activated ....12196
Failure code [989L00] Engine Controller Lock Caution 1 ....12197
Failure code [989M00] Engine Controller Lock Caution 2 ....12198
Failure code [989N00] Engine Controller Lock Caution 3 ....12199
Failure code [A1U0N3] HC Desorb Request 1 ....12200
Failure code [A1U0N4] HC Desorb Request 2 ....12202
Failure code [AA10NX] Air Cleaner Clogging ....12204
Failure code [B@BAZG] Eng Oil Press Low ....12206
Failure code [B@BAZK] Eng Oil Level Low ....12207
Failure code [B@BCNS] Eng Water Overheat ....12209
Failure code [B@BCZK] Eng Water Level Low ....12210
Failure code [B@CENS] T/C Oil Temp. Overheat ....12212
Failure code [B@HANS] HYD Oil Temp. Overheat ....12213
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ....12214
Failure code [CA122] Chg Air Press Sensor High Error ....12215
Failure code [CA123] Chg Air Press Sensor Low Error ....12217
Failure code [CA131] Throttle Sensor High Error ....12219
Failure code [CA132] Throttle Sensor Low Error ....12221
Failure code [CA135] Eng Oil Press Sensor High Error ....12223
Failure code [CA141] Eng Oil Press Sensor Low Error ....12225
Failure code [CA144] Coolant Temp Sens High Error ....12227
Failure code [CA145] Coolant Temp Sens Low Error ....12229
Failure code [CA153] Chg Air Temp Sensor High Error ....12231
Failure code [CA154] Chg Air Temp Sensor Low Error ....12233
Failure code [CA187] Sensor 2 Supply Volt Low Error ....12235
Failure code [CA221] Ambient Press Sensor High Error ....12237
Failure code [CA222] Ambient Press Sensor Low Error ....12239
Failure code [CA227] Sensor 2 Supply Volt High Error ....12241
Failure code [CA234] Eng Overspeed ....12242
Failure code [CA238] Ne Speed Sensor Supply Volt Error ....12243
Failure code [CA239] Ne Speed Sens Supply Volt High Error ....12244
Failure code [CA271] IMV/PCV1 Short Error ....12245
Failure code [CA272] IMV/PCV1 Open Error ....12246
Failure code [CA273] PCV2 Short Error ....12247
Failure code [CA274] PCV2 Open Error ....12248
Failure code [CA322] Inj #1(L#1) Open/Short Error ....12249
Failure code [CA323] Inj #5(L#5) Open/Short Error ....12251
Failure code [CA324] Inj #3(L#3) Open/Short Error ....12253
Failure code [CA325] Inj #6(L#6) Open/Short Error ....12255
Failure code [CA331] Inj #2(L#2) Open/Short Error ....12257
Failure code [CA332] Inj #4(L#4) Open/Short Error ....12259
Failure code [CA343] ECM Critical Internal Failure ....12261
Failure code [CA351] Injectors Drive Circuit Error ....12262
Failure code [CA352] Sensor 1 Supply Volt Low Error ....12263
Failure code [CA356] Mass Air Flow Sensor High Error ....12265
Failure code [CA357] Mass Air Flow Sensor Low Error ....12267
Failure code [CA386] Sensor 1 Supply Volt High Error ....12269
Failure code [CA431] Idle Validation Sw Error ....12270
Failure code [CA432] Idle Validation Process Error ....12273
Failure code [CA441] Battery Voltage Low Error ....12276
Failure code [CA442] Battery Voltage High Error ....12278
Failure code [CA449] Rail Press Very High Error ....12279
Failure code [CA451] Rail Press Sensor High Error ....12280
Failure code [CA452] Rail Press Sensor Low Error ....12282
Failure code [CA515] Rail Press Sens Sup Volt High Error ....12284
Failure code [CA516] Rail Press Sens Sup Volt Low Error ....12286
Failure code [CA553] Rail Press High Error ....12288
Failure code [CA555] Crankcase Press High Error 1 ....12289
Failure code [CA556] Crankcase Press High Error 2 ....12290
Failure code [CA559] Rail Press Low Error ....12291
Failure code [CA595] Turbo Speed High Error 2 ....12295
Failure code [CA687] Turbo Speed Low Error ....12296
Failure code [CA689] Eng Ne Speed Sensor Error ....12298
Failure code [CA691] Intake Air Temp Sens High Error ....12300
Failure code [CA692] Intake Air Temp Sens Low Error ....12302
Failure code [CA697] ECM Internal Temp Sensor High Error ....12304
Failure code [CA698] ECM Int Temp Sensor Low Error ....12305
Failure code [CA731] Eng Bkup Speed Sens Phase Error ....12306
Failure code [CA778] Eng Bkup Speed Sensor Error ....12307
Failure code [CA1117] Persistent Data Lost Error ....12309
Failure code [CA1664] KDOC Malfunction ....12310
Failure code [CA1691] Regeneration Ineffective ....12313
Failure code [CA1695] Sensor 5 Supply Volt High Error ....12316
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....12317
Failure code [CA1843] Crankcase Press Sens High Error ....12319
Failure code [CA1844] Crankcase Press Sens Low Error ....12321
Failure code [CA1879] KDPF Delta P Sensor High Error ....12323
Failure code [CA1881] KDPF Delta P Sensor Low Error ....12325
Failure code [CA1883] KDPF Delta P Sens In Range Error ....12327
Failure code [CA1921] KDPF Soot Load High Error 1 ....12330
Failure code [CA1922] KDPF Soot Load High Error 2 ....12333
Failure code [CA1923] Dosing Fuel Valve 1 High Error ....12338
Failure code [CA1924] Dosing Fuel Valve 1 Low Error ....12340
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ....12343
Failure code [CA1927] Dosing Fuel Press Sens High Error ....12345
Failure code [CA1928] Dosing Fuel Press Sens Low Error ....12347
Failure code [CA1942] Crankcase Press Sens In Range Error ....12349
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ....12350
Failure code [CA1977] Fuel Doser Open/Short Error ....12352
Failure code [CA1993] KDPF Delta Pressure Low Error ....12354
Failure code [CA2185] Throt Sensor Sup Volt High Error ....12356
Failure code [CA2186] Throt Sensor Sup Volt Low Error ....12358
Failure code [CA2249] Rail Press Very Low Error ....12360
Failure code [CA2265] Fuel Feed Pump Open Error ....12361
Failure code [CA2266] Fuel Feed Pump Short Error ....12363
Failure code [CA2271] EGR Valve Pos Sens High Error ....12365
Failure code [CA2272] EGR Valve Pos Sens Low Error ....12367
Failure code [CA2349] EGR Valve Solenoid Open Error ....12369
Failure code [CA2353] EGR Valve Solenoid Short Error ....12371
Failure code [CA2357] EGR Valve Servo Error ....12373
Failure code [CA2381] KVGT Pos Sens High Error ....12374
Failure code [CA2382] KVGT Pos Sens Low Error ....12376
Failure code [CA2383] KVGT Solenoid Open Error ....12378
Failure code [CA2386] KVGT Solenoid Short Error ....12380
Failure code [CA2387] KVGT Servo Error ....12382
Failure code [CA2555] Grid Htr Relay Volt Low Error ....12383
Failure code [CA2556] Grid Htr Relay Volt High Error ....12385
Failure code [CA2637] KDOC Face Plugging ....12387
Failure code [CA2639] Manual Stationary Regeneration Request ....12389
Failure code [CA2732] Dosing Fuel Valve 2 High Error ....12392
Failure code [CA2733] Dosing Fuel Valve 2 Low Error ....12394
Failure code [CA2741] Dosing Fuel Valve Swap Error ....12396
Failure code [CA2765] Inj Trim Data Error ....12398
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error ....12399
Failure code [CA2881] Dosing Fuel Pressure Low Error 1 ....12402
Failure code [CA3133] KDPF Outlet Press Sens High Error ....12407
Failure code [CA3134] KDPF Outlet Press Sens Low Error ....12409
Failure code [CA3135] KDPF Outlet Press Sens In Range Error ....12411
Failure code [CA3167] Fuel Doser Degradation ....12414
Failure code [CA3251] KDOC Inlet Temp High Error ....12417
Failure code [CA3253] KDOC Temp Error - Non Regeneration ....12420
Failure code [CA3254] KDOC Outlet Temp High Error 1 ....12423
Failure code [CA3255] KDPF Temp Error - Non Regeneration ....12426
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....12430
Failure code [CA3311] KDOC Outlet Temp High Error 2 ....12433
Failure code [CA3312] KDPF Outlet Temp High Error 2 ....12436
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ....12439
Failure code [CA3314] KDOC Inlet Temp Sens High Error ....12442
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ....12446
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ....12451
Failure code [CA3317] KDOC Outlet Temp Sens High Error ....12454
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ....12458
Failure code [CA3319] KDPF Outlet Temp Sens High Error ....12463
Failure code [CA3321] KDPF Outlet Temp Sens Low Error ....12467
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ....12470
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ....12475
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ....12477
Failure code [D150KA] Disconnection of Emerg. Steering Relay ....12479
Failure code [D150KB] Ground Fault of Emerg. Steering Relay ....12481
Failure code [D150KY] Hot Short of Emergency Steering Relay ....12483
Failure code [D160KA] Disconnection of Backup Lamp Relay Output ....12485
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output ....12487
Failure code [D160KY] Hot Short of Backup Lamp Relay Output ....12489
Failure code [D191KA] Disconnection of Neutral Output Relay ....12491
Failure code [D191KB] Ground Fault of Neutral Output Relay ....12493
Failure code [D191KY] Hot Short of Neutral Output Relay ....12495
Failure code [D192KA] Disconnection of ECSS Solenoid ....12497
Failure code [D192KB] Ground Fault of ECSS Solenoid ....12499
Failure code [D192KY] Hot Short of ECSS Solenoid ....12500
Failure code [D19JKZ] Personal Code Relay Abnormality ....12501
Failure code [D1E6KA] Disconnection of Parking Brake Relay ....12503
Failure code [D1E6KB] Ground Fault of Parking Brake Relay ....12505
Failure code [D1E6KY] Hot Short of Parking Brake Relay ....12507
Failure code [D5ZHKA] Failure of Key SW C Signal ....12509
Failure code [D5ZHKB] Key SW C Signal Short Circuit ....12511
Failure code [D5ZHKZ] Failure of Key SW C Signal ....12513
Failure code [D5ZHL6] Disconnection of Key SW C ....12515
Failure code [D811MC] KOMTRAX Error ....12517
Failure code [D862KA] GPS Antenna Open Circuit ....12518
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ....12519
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ....12521
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ....12523
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ....12524
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ....12526
Failure code [DAF0MB] Monitor ROM Abnormality ....12527
Failure code [DAF0MC] Monitor Error ....12528
Failure code [DAF3KK] Controller Power Source Low (MON) ....12529
Failure code [DAF8KB] Camera Power Supply Short Circuit ....12531
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit ....12532
Failure code [DAFGMC] GPS Module Error ....12534
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ....12535
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) ....12537
Failure code [DAFQKR] CAN2 Discon (Monitor) ....12539
Failure code [DAQ0KK] Controller Power Source Low (T/M) ....12540
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ....12543
Failure code [DAQ0MC] T/M Con Error ....12544
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) ....12545
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ....12547
Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay ....12550
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) ....12552
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) ....12553
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ....12555
Failure code [DAQQKR] CAN2 Discon (Transmission Con) ....12557
Failure code [DAQRKR] CAN1 Discon (Transmission Con) ....12558
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ....12559
Failure code [DAZ9KQ] A/C Model Selection Abnormality ....12560
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ....12561
Failure code [DB2QKR] CAN2 Discon (Engine Con) ....12562
Failure code [DB2RKR] CAN1 Discon (Engine Con) ....12567
Failure code [DB90KK] Drop in BBC Controller Main Power Source ....12572
Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) ....12574
Failure code [DB90MC] BBC Error ....12575
Failure code [DB91KA] Disconnection of Key SW ACC (BBC) ....12576
Failure code [DB92KK] Solenoid Power Source Low (BBC) ....12578
Failure code [DB95KX] Failure of 5 V Power Source 1 ....12580
Failure code [DB96KX] Failure of 5 V Power Source 2 ....12582
Failure code [DB99KQ] Inconsistency of Model Selection (BBC) ....12584
Failure code [DB9LKA] Operating Lamp Open Circuit (BBC) ....12585
Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) ....12587
Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) ....12589
Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) ....12590
Failure code [DB9RMA] Inconsistency of Option Selection (BBC) ....12591
Failure code [DBE5KX] Failure of 5V Power Source ....12592
Failure code [DBE6KX] Failure of 24 V Power Source ....12594
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ....12596
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ....12598
Failure code [DDB6L4] Neutral Signal Malfunction ....12600
Failure code [DDD1LD] Failure of Bucket Positioner Set Switch ....12603
Failure code [DDK3KA] FNR SW Input Signal Disconnection ....12605
Failure code [DDK3KB] FNR SW Input Signal Short Circuit ....12608
Failure code [DDK6KA] FNR Lever Input Signal Disconnection ....12610
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ....12613
Failure code [DDNRKY] Hot Short of Work Equipment Lock SW ....12615
Failure code [DDT0L4] Failure of Shift Mode Select SW ....12617
Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal ....12619
Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal ....12621
Failure code [DDW9LD] Ground Fault of Kickdown Switch ....12623
Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW ....12625
Failure code [DF10KA] Disconnection of Shift Lever Input ....12627
Failure code [DF10KB] Ground Fault of Shift Lever Input ....12629
Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor ....12632
Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor ....12634
Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor ....12636
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ....12638
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor ....12639
Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor ....12641
Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor ....12644
Failure code [DH21KA] Failure of Loader Pump Press. Sensor ....12646
Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit ....12648
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit ....12650
Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor ....12652
Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor ....12654
Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor ....12656
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor ....12658
Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor ....12660
Failure code [DHT8KA] Failure of Steering Pump Press. Sensor ....12662
Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit ....12664
Failure code [DHT8ZG] Steering Oil Pressure Low ....12666
Failure code [DHUDKA] Failure of Emrg. Steering Press. Sensor ....12667
Failure code [DHUDKB] Emrg. Steering Press. S. Short Circuit ....12669
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ....12671
Failure code [DK55KA] Failure of FNR Lever Potentio ....12673
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ....12676
Failure code [DK55L5] Failure of FNR Lever Potentio ....12678
Failure code [DK59KA] Failure of Boom Lever Potentio (Main) ....12679
Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) ....12682
Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree ....12685
Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub) ....12689
Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) ....12692
Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) ....12695
Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) ....12698
Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree ....12701
Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) ....12705
Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) ....12708
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ....12711
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ....12714
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ....12716
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) ....12719
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) ....12722
Failure code [DKA0KA] Failure of Boom Angle Sensor ....12724
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit ....12726
Failure code [DKA0L0] Boom Angle Sensor Dislocation ....12728
Failure code [DKA1KA] Failure of Bucket Angle Sensor ....12730
Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit ....12732
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor ....12734
Failure code [DLF1LC] Failure of T/M Input Speed Sensor ....12736
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor ....12738
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ....12740
Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main) ....12742
Failure code [DLT3LC] Failure of Output Speed Sensor (Main) ....12744
Failure code [DPQ1KR] LIN Discon (Switch Panel) ....12746
Failure code [DPQ2KR] LIN Discon (LED Unit) ....12749
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ....12752
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ....12755
Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator ....12757
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ....12759
Failure code [DV00KB] Ground Fault of Buzzer Output ....12761
Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) ....12763
Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise) ....12765
Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) ....12767
Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) ....12769
Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) ....12771
Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) ....12773
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ....12775
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) ....12777
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ....12779
Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) ....12781
Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) ....12783
Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) ....12785
Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid ....12787
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. ....12789
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. ....12791
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ....12792
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid ....12794
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ....12796
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ....12798
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ....12800
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ....12802
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ....12804
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ....12806
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ....12808
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. ....12810
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ....12812
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ....12814
Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid ....12816
Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid ....12818
Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid ....12820
Failure code [DXANKA] Disconnection of Steering Pump EPC Sol. ....12822
Failure code [DXANKB] Ground Fault of Steering Pump EPC Solenoid ....12824
Failure code [DXANKY] Hot Short of Steering Pump EPC Solenoid ....12826
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ....12827
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ....12829
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) ....12831
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) ....12833
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) ....12835
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) ....12837
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) ....12839
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) ....12841
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) ....12843
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ....12845
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) ....12847
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) ....12849
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) ....12851
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ....12853
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) ....12855
Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) ....12857
Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward) ....12859
Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) ....12861
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) ....12863
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) ....12865
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) ....12867
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ....12869
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) ....12871
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ....12873
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ....12875
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ....12877
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ....12879
Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor ....12881
Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor ....12884
Failure code [DY30ME] Emerg. Steering Long-Time Activated ....12888
Failure code [LA00L3] Failure of Fan Reverse ....12890
Troubleshooting of electrical system (E-mode) ....12891
E-1 Engine does not start ....12891
E-2 Manual preheating system does not work ....12897
E-3 Automatic preheating system does not work ....12900
E-4 While preheating is working, preheating monitor does not light up ....12902
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing ....12904
E-6 LCD unit on machine monitor displays nothing ....12907
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ....12909
E-8 LCD on machine monitor does not display properly ....12911
E-9 Meter unit display on machine monitor is abnormal ....12913
E-10 Night lighting lamp of meter unit on machine monitor is abnormal ....12916
E-11 Caution LED on machine monitor is abnormal ....12919
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ....12921
E-13 Two switches operation of switch panel on machine monitor does not function ....12923
E-14 Switch panel buzzer of machine monitor is abnormal ....12926
E-15 Rear view monitor does not light up or backlight flickers ....12928
E-16 Rear view monitor images are not displayed clearly ....12931
E-17 Rear view monitor brightness cannot be adjusted ....12934
E-18 Night lighting lamp of rear view monitor is abnormal ....12937
E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ....12939
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position ....12940
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light ....12944
E-22 Air cleaner clogging indicator lamp does not light ....12946
E-23 Radiator coolant level caution lamp does not light ....12947
E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil temperature caution lamp does not light ....12949
E-25 Indication of torque converter oil temperature gauge does not increase, or torque converter oil temperature caution lamp does not light ....12951
E-26 Fuel level gauge does not indicate correct level ....12952
E-27 Seat belt caution lamp indication is abnormal ....12954
E-28 Horn does not sound ....12955
E-29 Horn does not stop sounding ....12958
E-30 Alarm buzzer does not sound ....12960
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ....12961
E-32 Kickdown does not work when kickdown switch is turned ON ....12962
E-33 The hold switch does not work when it is pressed ....12964
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 ....12966
E-35 Transmission cut-off mode is not selected or not released ....12969
E-36 Transmission cut-off setting cannot be released ....12971
E-37 Directional selector (FNR) switch mode is not selected or not released ....12973
E-38 When operating engine power selection switch, engine power selection function does not operate properly ....12975
E-39 Flow of loader pump does not increase from the minimum rate ....12977
E-40 ECSS function cannot be selected or cannot be released ....12978
E-41 None of headlamp, clearance lamp, and tail lamp lights ....12980
E-42 Clearance lamp and tail lamp do not light up or go out ....12982
E-43 Both High and Low beams of headlamp do not light up or go out ....12985
E-44 Low beam of headlamp does not light up or go out ....12989
E-45 High beam of headlamp does not light up or go out ....12991
E-46 Front working lamp does not light up or go out ....12993
E-47 Rear working lamp does not light up or go out ....12996
E-48 All of turn signal lamps and hazard lamps do not light up or go out ....12999
E-49 Turn signal lamps do not light up or go out ....13002
E-50 Hazard lamp does not light up or go out ....13005
E-51 Brake lamp does not light or stays lighted ....13008
E-52 Backup lamp does not light up or does not go out ....13011
E-53 Backup buzzer does not sound or continues to sound ....13014
E-54 Front wiper does not operate ....13016
E-55 Rear wiper does not operate ....13019
E-56 Window washer does not operate ....13021
E-57 Fuel feed pump does not operate or stop automatically ....13024
E-58 KOMTRAX system does not operate properly ....13026
Troubleshooting of hydraulic and mechanical system (H-mode) ....13028
Information described in troubleshooting table (H-mode) ....13028
System chart of hydraulic and mechanical systems ....13029
Failure mode and cause table ....13032
H-1 Machine does not move off ....13040
H-2 Torque converter lockup clutch is not disengaged (engine stalls) ....13043
H-3 Torque converter lockup clutch is not engaged ....13044
H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift ....13045
H-5 Large shock is made when machine starts or gear is shifted ....13048
H-6 Machine starts or gear speed shifts with long time lag ....13050
H-7 Torque converter oil temperature is high ....13052
H-8 Machine does not turn ....13054
H-9 Turning response is poor ....13056
H-10 Steering wheel is heavy to turn ....13058
H-11 Machine sways or large shocks are made while machine turns ....13059
H-12 Turning radius differs between right and left turns ....13061
H-13 Wheel brakes do not work or are weak ....13062
H-14 Wheel brakes are not released or drag ....13064
H-15 Parking brake does not work or it is weak ....13065
H-16 Parking brake is not released or drags (including emergency release system) ....13066
H-17 Boom does not rise ....13067
H-18 Boom moves slow or boom lacks lifting force ....13069
H-19 Rising boom slows down at certain height ....13071
H-20 Lift cylinders do not serve to hold bucket on ground ....13072
H-21 Hydraulic drift of boom is large ....13073
H-22 Boom moves up and down during operation ....13074
H-23 Bucket does not tilt back ....13075
H-24 Bucket moves slow or lacks tilt-back force ....13077
H-25 Bucket decelerates during tilt-back operation ....13079
H-26 Bucket cylinder does not hold bucket on ground ....13080
H-27 Hydraulic drift of bucket is large ....13081
H-28 Bucket tilts back and forth during carrying load (work equipment valve in HOLD) ....13082
H-29 Boom and bucket control levers do not move smoothly and are heavy to move ....13083
H-30 Operating work equipment causes engine speed to lower significantly or engine to stall ....13084
H-31 Large shocks are made when work equipment starts to move and stops ....13085
H-32 When certain work equipment stalls hydraulically, other work equipment moves ....13087
H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces ....13088
H-34 Bucket does not stop at the position which is set with remote bucket positioner ....13089
H-35 Fan speed is abnormal (too high or low, or fan does not rotate) ....13090
H-36 Unusual noise is heard from around fan ....13091
Troubleshooting of engine (S-mode) ....13092
Information mentioned in troubleshooting table (S mode) ....13092
S-1 When starting switch is turned to START position, engine is not cranked ....13093
S-2 The engine cranks but exhaust smoke does not come out ....13094
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) ....13095
S-4 Engine startability is poor ....13096
S-5 Engine does not pick-up smoothly ....13098
S-6 Engine stops during operation ....13100
S-7 Engine runs rough or is unstable ....13102
S-8 Engine lacks power ....13103
S-9 KDPF gets clogged in a short time ....13105
S-10 Engine oil consumption is excessive ....13107
S-11 Engine oil becomes contaminated early ....13108
S-12 Fuel consumption is excessive ....13109
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ....13110
S-14 Oil pressure drops ....13111
S-15 Fuel mixes into engine oil ....13112
S-16 Water mixes into engine oil (milky) ....13113
S-17 Coolant temperature rises too high (overheating) ....13114
S-18 Unusual noise is heard ....13115
S-19 Vibration is excessive ....13116
S-20 Air cannot be bled from fuel circuit ....13117
S-21 Active regeneration is executed frequently ....13118
S-22 Active regeneration takes a long time ....13119
S-23 White smoke is exhausted during active regeneration ....13120
50 Disassembly and assembly ....13122
Table of contents ....13123
General information on disassembly and assembly ....13125
How to read this manual ....13125
Coating materials list ....13127
Special tools list ....13131
Sketches of special tools ....13138
Engine and cooling system ....13168
Removal and installation of supply pump assembly ....13168
Removal and installation of injector assembly ....13174
Removal and installation of fuel doser assembly ....13182
Removal and installation of cylinder head assembly ....13184
Removal and installation of engine hood assembly ....13198
Removal and installation of grille assembly ....13200
Removal and installation of cooling system assembly ....13203
Removal and installation of radiator core assembly ....13206
Removal and installation of aftercooler ....13208
Removal and installation of hydraulic oil cooler ....13211
Removal and installation of power train oil cooler assembly ....13213
Removal and installation of engine assembly ....13217
Removal and installation of engine front oil seal ....13223
Removal and installation of engine rear oil seal ....13226
Removal and installation of cooling fan and cooling fan motor assembly ....13231
Removal and installation of KDPF assembly ....13233
Disassembly and assembly of KDPF assembly ....13238
Removal and installation of KCCV assembly ....13247
Removal and installation of KVGT assembly ....13249
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ....13254
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ....13255
Removal and installation of air cleaner assembly ....13257
Removal and installation of air conditioner compressor belt ....13259
Removal and installation of alternator belt ....13260
Removal and installation of fuel tank assembly ....13261
Power train ....13264
Removal and installation of torque converter and transmission assembly ....13264
Disassembly and assembly of transmission assembly ....13269
Disassembly and assembly of torque converter assembly ....13299
Disassembly and assembly of transmission clutch pack assembly ....13306
Removal and installation of front axle assembly ....13329
Removal and installation of rear axle assembly ....13331
Disassembly and assembly of axle housing assembly ....13336
Disassembly and assembly of differential assembly ....13346
Steering system ....13365
Removal and installation of steering valve assembly ....13365
Brake system ....13367
Removal and installation of brake charge valve assembly ....13367
Removal and installation of parking brake disc and plate ....13368
Undercarriage and frame ....13371
Removal and installation of center hinge pin ....13371
Removal and installation of counterweight assembly ....13379
Removal and installation of full-length fender assembly ....13381
Hydraulic system ....13382
Removal and installation of hydraulic tank assembly ....13382
Removal and installation of control valve assembly ....13385
Removal and installation of steering pump and power train pump assembly ....13388
Removal and installation of work equipment pump and cooling fan pump assembly ....13390
Disassembly and assembly of hydraulic cylinder assembly ....13392
Work equipment ....13399
Removal and installation of work equipment assembly ....13399
Cab and its attachments ....13404
Removal and installation of operator's cab and floor frame assembly ....13404
Removal and installation of operator's cab glass (stuck window glass) ....13408
Removal and installation of operator's seat assembly ....13416
Removal and installation of seat belt ....13418
Removal and installation of air conditioner unit assembly ....13419
Removal and installation of air conditioner compressor assembly ....13424
Removal and installation of air conditioner condenser assembly ....13426
Electrical system ....13428
Removal and installation of machine monitor assembly ....13428
Removal and installation of engine controller assembly ....13429
Removal and installation of work equipment controller assembly ....13430
Removal and installation of transmission controller assembly ....13432
Removal and installation of monitor controller assembly ....13433
Removal and installation of mass air flow and temperature sensor ....13435
Removal and installation of KOMTRAX terminal assembly ....13436
60 Maintenance standard ....13438
Table of contents ....13439
Engine and cooling system ....13440
Engine related parts ....13440
Cooling fan pump ....13441
Cooling fan motor ....13444
Power train ....13446
Drive shaft ....13446
Torque converter ....13447
Transmission ....13449
Transmission control valve ....13458
Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV ....13460
3rd, 4th clutch ECMV ....13461
Lockup clutch ECMV ....13462
Main relief and torque converter relief valve ....13463
Axle ....13464
Differential ....13466
Final drive ....13476
Steering system ....13478
Steering column ....13478
Steering pump ....13479
Steering valve ....13483
Steering cylinder ....13485
Emergency steering pump ....13488
Brake system ....13489
Charge valve ....13489
Slack adjuster ....13491
Brake ....13492
Parking brake ....13494
Parking brake solenoid valve ....13495
Undercarriage and frame ....13496
Axle mount and center hinge pin ....13496
Hydraulic system ....13500
Hydraulic tank ....13500
Double type gear pump ....13501
Work equipment pump ....13502
Control valve ....13504
Work equipment ....13513
Work equipment linkage ....13513
Bucket ....13517
Work equipment cylinder ....13518
80 Appendix ....13520
Table of contents ....13521
Air conditioner components ....13522
Precautions for refrigerant ....13522
Air conditioner component ....13523
Configuration and function of refrigeration cycle ....13525
Outline of refrigeration cycle ....13526
Air conditioner unit ....13528
Dual pressure switch ....13533
Air conditioner controller ....13534
Compressor ....13535
Condenser ....13536
Receiver drier ....13537
Sunlight sensor ....13539
Outer temperature sensor (outside air temperature sensor) ....13540
Procedure for testing and troubleshooting ....13541
Circuit diagram and arrangement of connector pins ....13543
System diagram ....13546
Parts and connectors layout ....13549
Testing with self-diagnosis function ....13554
How to open the electrical system abnormality record screen in service mode of the machine monitor ....13555
Testing temperature control system ....13557
Testing vent (mode) changeover ....13559
Testing FRESH/RECIRC air changeover ....13561
Check evaporator temperature sensor ....13563
Testing relays ....13565
Troubleshooting chart 1 ....13567
Troubleshooting chart 2 ....13568
Information in troubleshooting table ....13570
Failure code list related to air conditioner ....13571
Failure code [879AKA] A/C Inner Sensor Open Circuit ....13572
Failure code [879AKB] A/C Inner Sensor Short Circuit ....13574
Failure code [879BKA] A/C Outer Sensor Open Circuit ....13576
Failure code [879BKB] A/C Outer Sensor Short Circuit ....13578
Failure code [879CKA] Ventilating Sensor Open Circuit ....13580
Failure code [879CKB] Ventilating Sensor Short Circuit ....13582
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ....13584
Failure code [879EMC] Ventilation Damper Abnormality ....13586
Failure code [879FMC] Air Mix Damper Abnormality ....13589
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) ....13592
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ....13595
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ....13598
A-4 Troubleshooting for FRESH/RECIRC air changeover ....13601
Troubleshooting with gauge pressure ....13603
Connection of service tool ....13606
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ....13608
Handling of compressor oil ....13610
90 Diagrams and drawings ....13612
Table of contents ....13613
Hydraulic circuit diagram ....13614
Symbols in hydraulic circuit diagram ....13614
Hydraulic circuit diagram of power train ....13618
Hydraulic circuit diagram ....13620
Electric circuit diagram ....13621
Symbols in electric circuit diagram ....13621
Electrical circuit diagram of machine body ....13625
Electrical circuit diagram of floor ....13630
SEN06514-08 - Wheel Loader WA470-8 Shop Manual....13652
COVER....13652
00 INDEX AND FOREWORD....13654
INDEX....13655
ABBREVIATION LIST....13675
FOREWORD, SAFETY, BASIC INFORMATION....13681
HOW TO READ THE SHOP MANUAL....13681
SAFETY NOTICE FOR OPERATION....13683
PRECAUTIONS TO PREVENT FIRE....13691
ACTIONS IF FIRE OCCURS....13693
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS....13694
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS....13695
PRECAUTIONS FOR DEF....13696
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING....13696
PRECAUTIONS FOR ADDING....13696
PRECAUTIONS FOR STORING....13696
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE....13696
THE OTHER PRECAUTIONS....13696
STORE AdBlue/DEF....13697
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT....13698
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS....13701
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT....13707
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT....13709
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT....13710
PRACTICAL USE OF KOMTRAX....13711
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER....13712
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER....13712
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER....13713
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER....13714
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS....13716
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR....13720
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR....13721
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL....13723
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH....13724
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE....13726
HOW TO READ ELECTRICAL WIRE CODE....13727
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD....13731
STANDARD TIGHTENING TORQUE TABLE....13734
CONVERSION TABLE....13741
01 SPECIFICATIONS....13746
CONTENTS....13747
ABBREVIATION LIST....13748
SPECIFICATIONS....13754
SPECIFICATION DRAWING....13754
SPECIFICATION DRAWING: WA470-8....13754
SPECIFICATIONS....13756
SPECIFICATIONS: WA470-8....13756
WEIGHT TABLE....13761
WEIGHT TABLE:WA470-8....13761
TABLE OF FUEL, COOLANT, AND LUBRICANTS....13763
10 STRUCTURE AND FUNCTION....13766
CONTENTS....13767
ABBREVIATION LIST....13772
UREA SCR SYSTEM....13778
LAYOUT DRAWING OF UREA SCR SYSTEM....13778
UREA SCR SYSTEM DIAGRAM....13782
FUNCTION OF UREA SCR SYSTEM....13783
FUNCTION OF AdBlue/DEF SYSTEM....13783
INDUCEMENT STRATEGY....13785
COMPONENT PARTS OF UREA SCR SYSTEM....13800
AdBlue/DEF MIXING TUBE....13800
SCR ASSEMBLY....13801
AdBlue/DEF TANK....13803
AdBlue/DEF PUMP....13805
AdBlue/DEF INJECTOR....13806
AdBlue/DEF HOSE....13807
AdBlue/DEF TANK HEATING VALVE....13808
BOOT-UP SYSTEM....13809
LAYOUT DRAWING OF BOOT-UP SYSTEM....13809
SYSTEM OPERATING LAMP SYSTEM....13811
SYSTEM OPERATING LAMP SYSTEM DIAGRAM....13811
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM....13811
BATTERY DISCONNECT SWITCH....13812
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH....13812
FUNCTION OF BATTERY DISCONNECT SWITCH....13812
PREHEATING SYSTEM....13814
PREHEATING SYSTEM DIAGRAM....13814
FUNCTION OF AUTOMATIC PREHEATING SYSTEM....13814
OPERATION OF AUTOMATIC PREHEATING SYSTEM....13814
FUNCTION OF MANUAL PREHEATING SYSTEM....13815
OPERATION OF MANUAL PREHEATING SYSTEM....13815
ENGINE SYSTEM....13816
LAYOUT DRAWING OF ENGINE SYSTEM....13816
FUNCTION OF ENGINE SYSTEM....13818
ENGINE CONTROL SYSTEM....13819
ENGINE CONTROL SYSTEM DIAGRAM....13819
FUNCTION OF ENGINE CONTROL SYSTEM....13820
OPERATION OF ENGINE CONTROL SYSTEM....13823
ENGINE POWER MODE SELECTOR SYSTEM....13825
ENGINE POWER MODE SELECTOR SYSTEM DIAGRAM....13825
FUNCTION OF ENGINE POWER MODE SELECTOR SYSTEM....13825
OPERATION OF ENGINE POWER MODE SELECTOR SYSTEM....13825
AUTOMATIC IDLE STOP SYSTEM....13827
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM....13827
COMPONENT PARTS OF ENGINE SYSTEM....13828
VGT....13828
EGR SYSTEM....13832
EGR VALVE....13834
EGR COOLER....13836
KCCV SYSTEM....13837
KCCV VENTILATOR....13839
KDPF....13841
COOLING SYSTEM....13845
LAYOUT DRAWING OF COOLING SYSTEM....13845
SPECIFICATIONS OF COOLING SYSTEM....13846
COOLING FAN CONTROL SYSTEM....13848
COOLING FAN CONTROL SYSTEM DIAGRAM....13848
FUNCTION OF COOLING FAN CONTROL SYSTEM....13848
COMPONENT PARTS OF COOLING SYSTEM....13853
BRAKE AND COOLING FAN PUMP....13853
COOLING FAN MOTOR....13861
CONTROL SYSTEM....13867
LAYOUT DRAWING OF CONTROL SYSTEM....13867
MACHINE MONITOR SYSTEM....13869
MACHINE MONITOR SYSTEM DIAGRAM....13869
FUNCTION OF MACHINE MONITOR SYSTEM....13869
REARVIEW MONITOR SYSTEM....13871
REARVIEW MONITOR SYSTEM DIAGRAM....13871
FUNCTION OF REARVIEW MONITOR SYSTEM....13871
KOMTRAX SYSTEM....13872
KOMTRAX SYSTEM DIAGRAM....13872
FUNCTION OF KOMTRAX SYSTEM....13872
COMPONENT PARTS OF CONTROL SYSTEM....13873
MACHINE MONITOR....13873
SWITCH PANEL....13893
REARVIEW MONITOR....13894
REARVIEW CAMERA....13896
KOMTRAX TERMINAL....13897
TRANSMISSION CONTROLLER....13899
WORK EQUIPMENT CONTROLLER....13903
MONITOR CONTROLLER....13907
CAN TERMINATING RESISTOR....13912
ENGINE CONTROLLER....13913
ACCELERATOR PEDAL....13920
HYDRAULIC SYSTEM....13922
LAYOUT DRAWING OF HYDRAULIC SYSTEM....13922
CLSS....13923
STRUCTURE OF CLSS....13923
FUNCTION OF CLSS....13924
WORK EQUIPMENT PUMP AND STEERING PUMP CONTROL SYSTEM....13926
SWASH PLATE CONTROL FUNCTION OF WORK EQUIPMENT PUMP AND STEERING PUMP....13926
PICKUP ASSISTANCE CONTROL FUNCTION WHEN ENGINE SPEED IS LOW....13926
OVERHEAT PREVENTION FUNCTION OF WORK EQUIPMENT CIRCUIT....13926
COMPONENT PARTS OF HYDRAULIC SYSTEM....13927
HYDRAULIC TANK....13927
WORK EQUIPMENT PUMP....13930
STEERING PUMP....13948
POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP....13960
CONTROL VALVE....13961
POWER TRAIN SYSTEM....13995
LAYOUT DRAWING OF POWER TRAIN SYSTEM....13995
OPERATION OF POWER TRAIN SYSTEM....13998
TRANSMISSION CONTROL SYSTEM....13999
TRANSMISSION CONTROL SYSTEM DIAGRAM....13999
TRANSMISSION GEAR SHIFT CONTROL SYSTEM....14001
ELECTRIC MODULATION FUNCTION SYSTEM DIAGRAM....14001
ELECTRIC MODULATION FUNCTION....14002
DISPLAY FUNCTION OF GEAR SHIFT....14002
AUTOMATIC GEAR SHIFT FUNCTION....14002
SHIFT HOLD FUNCTION....14003
KICKDOWN FUNCTION....14003
AUTOMATIC KICKDOWN FUNCTION....14004
TORQUE CONVERTER LOCKUP FUNCTION....14004
HUNTING PREVENTION FUNCTION....14005
ADJUSTING FUNCTION OF TRANSMISSION INITIAL LEARNING AND ECMV CURRENT....14005
SHIFT POINT CHANGING FUNCTION....14005
4TH GEAR SPEED LIMITATION FUNCTION....14005
TRANSMISSION PROTECTION FUNCTION....14007
PROTECTION FUNCTION WHEN TRAVEL DIRECTION IS CHANGED....14007
SHIFT DOWN PROTECTION FUNCTION....14007
ENGINE OVERRUN PREVENTION FUNCTION....14008
MAXIMUM SPEED LIMITATION FUNCTION....14008
NEUTRALIZER FUNCTION....14008
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION....14010
TRANSMISSION CUT-OFF FUNCTION....14012
COMPONENT PARTS OF POWER TRAIN SYSTEM....14014
DRIVE SHAFT....14014
TORQUE CONVERTER....14016
LOCKUP CLUTCH ECMV....14019
TRANSMISSION....14022
TRANSMISSION CONTROL VALVE....14039
FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND CLUTCH ECMV....14042
3RD AND 4TH CLUTCH ECMV....14047
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE....14052
AXLE....14054
CONVENTIONAL DIFFERENTIAL....14056
LIMITED SLIP DIFFERENTIAL....14059
FINAL DRIVE....14064
COMBINATION SWITCH....14066
SHIFT HOLD SWITCH....14070
KICKDOWN SWITCH....14071
WORK EQUIPMENT SYSTEM....14072
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM....14072
WORK EQUIPMENT SYSTEM DIAGRAM....14074
WORK EQUIPMENT CONTROL SYSTEM....14076
WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE....14076
WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION....14076
WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM....14077
WORK EQUIPMENT LEVER OPERATION FUNCTION....14078
BUCKET PRIORITY CONTROL FUNCTION....14078
BOOM STOP MODULATION FUNCTION....14078
WORK EQUIPMENT NEUTRAL LOCK SYSTEM....14080
WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM....14080
FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM....14080
REMOTE POSITIONER SYSTEM....14082
REMOTE BUCKET POSITIONER SYSTEM DIAGRAM....14082
FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM....14082
REMOTE BOOM POSITIONER SYSTEM DIAGRAM....14083
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM....14083
BUCKET POSITIONER AND BOOM POSITIONER....14087
STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER....14087
AUTO-DIGGING SYSTEM....14088
AUTO-DIGGING SYSTEM DIAGRAM....14088
FUNCTION OF AUTO-DIGGING SYSTEM....14088
SEMI AUTO-DIGGING SYSTEM....14090
SEMI AUTO-DIGGING SYSTEM DIAGRAM....14090
FUNCTION OF SEMI AUTO-DIGGING SYSTEM....14090
ECSS....14092
ECSS DIAGRAM....14092
FUNCTION OF ECSS....14092
OPERATION OF ECSS....14092
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM....14094
WORK EQUIPMENT LOCK SOLENOID VALVE....14094
PILOT CIRCUIT ACCUMULATOR....14095
ECSS CIRCUIT ACCUMULATOR....14096
WORK EQUIPMENT ELECTRIC LEVER....14098
MULTIFUNCTION MONO-LEVER....14101
STEERING SYSTEM....14102
LAYOUT DRAWING OF STEERING SYSTEM....14102
SECONDARY STEERING SYSTEM....14103
SECONDARY STEERING SYSTEM DIAGRAM....14103
FUNCTION OF SECONDARY STEERING SYSTEM....14103
JOYSTICK STEERING SYSTEM....14105
FUNCTION OF JOYSTICK STEERING SYSTEM....14105
JOYSTICK CONTROL FUNCTION....14105
JOYSTICK NEUTRAL SAFETY FUNCTION....14108
JOYSTICK NEUTRAL INTERLOCK FUNCTION....14108
JOYSTICK SPEED SENSING STEERING FUNCTION....14108
JOYSTICK Hi/Lo SELECTOR FUNCTION....14109
STEERING COLUMN....14110
STRUCTURE OF STEERING COLUMN....14110
COMPONENT PARTS OF STEERING SYSTEM....14111
ORBITROL VALVE....14112
STOP VALVE....14116
STEERING VALVE....14117
SECONDARY STEERING PUMP....14130
SECONDARY STEERING MOTOR....14131
JOYSTICK KNOB....14132
BRAKE SYSTEM....14133
LAYOUT DRAWING OF BRAKE SYSTEM....14133
LAYOUT DRAWING OF BRAKE COOLING SYSTEM....14134
PARKING BRAKE CONTROL SYSTEM....14137
PARKING BRAKE CONTROL SYSTEM DIAGRAM....14137
OPERATION OF PARKING BRAKE CONTROL SYSTEM....14137
BRAKE COOLING CONTROL SYSTEM....14139
BRAKE COOLING CONTROL SYSTEM DIAGRAM....14139
FUNCTION OF BRAKE COOLING CONTROL SYSTEM....14140
COMPONENT PARTS OF BRAKE SYSTEM....14141
CHARGE VALVE....14141
PARKING BRAKE SOLENOID VALVE....14147
PARKING BRAKE EMERGENCY RELEASE VALVE....14149
BRAKE CIRCUIT ACCUMULATOR....14150
BRAKE VALVE....14152
SLACK ADJUSTER....14156
BRAKE....14158
PARKING BRAKE....14161
FLOW PRIORITY VALVE....14163
BRAKE COOLING MOTOR....14165
BRAKE COOLING PUMP....14168
BRAKE COOLING OIL COOLER....14169
AUTO-GREASING SYSTEM....14170
LAYOUT DRAWING OF AUTO-GREASING SYSTEM....14170
SPECIFICATIONS OF AUTO-GREASING SYSTEM....14172
FUNCTION OF AUTO-GREASING SYSTEM....14174
COMPONENT PARTS OF AUTO-GREASING SYSTEM....14175
AUTO-GREASING PUMP....14175
UNDERCARRIAGE AND FRAME....14176
FRAME, AXLE MOUNT AND CENTER HINGE PIN....14176
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN....14176
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN....14176
TIRE....14178
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE....14178
STRUCTURE OF RADIAL TIRE....14178
FUNCTION OF RADIAL TIRE....14178
STRUCTURE OF BIAS TIRE....14179
FUNCTION OF BIAS TIRE....14179
WORK EQUIPMENT....14180
STRUCTURE OF WORK EQUIPMENT....14180
STRUCTURE OF BUCKET....14181
CAB AND ITS ATTACHMENTS....14182
ROPS CAB....14182
STRUCTURE OF ROPS CAB....14182
FUNCTION OF ROPS CAB....14182
20 STANDARD VALUE TABLE....14184
CONTENTS....14185
ABBREVIATION LIST....14186
STANDARD VALUE TABLE FOR ENGINE....14192
STANDARD VALUE TABLE FOR ENGINE: WA470-8....14192
STANDARD VALUE TABLE FOR MACHINE....14196
STANDARD VALUE TABLE FOR MACHINE: WA470-8....14196
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE....14215
STANDARD VALUE TABLE FOR ELECTRICAL....14218
STANDARD VALUE TABLE FOR ELECTRICITY....14218
30 TESTING AND ADJUSTING....14238
CONTENTS....14239
ABBREVIATION LIST....14243
RELATED INFORMATION ON TESTING AND ADJUSTING....14249
TOOLS FOR TESTING AND ADJUSTING....14249
SKETCH OF TOOLS FOR TESTING AND ADJUSTING....14258
ENGINE AND COOLING SYSTEM....14260
TEST ENGINE SPEED....14260
METHOD FOR TESTING ENGINE SPEED....14260
TEST BOOST PRESSURE....14266
METHOD FOR TESTING BOOST PRESSURE....14266
TESTING EXHAUST GAS TEMPERATURE....14269
METHOD FOR TESTING EXHAUST GAS TEMPERATURE....14269
TEST EXHAUST GAS COLOR....14271
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER....14271
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER....14273
TEST AND ADJUST VALVE CLEARANCE....14274
METHOD FOR TESTING VALVE CLEARANCE....14274
METHOD FOR ADJUSTING VALVE CLEARANCE....14276
TEST COMPRESSION PRESSURE....14277
METHOD FOR TESTING COMPRESSION PRESSURE....14277
TEST BLOWBY PRESSURE....14281
METHOD FOR TESTING BLOWBY PRESSURE....14281
TEST ENGINE OIL PRESSURE....14284
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR....14284
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL....14285
TEST EGR VALVE AND KVGT OIL PRESSURE....14286
METHOD FOR TESTING EGR VALVE AND KVGT OIL PRESSURE....14286
TEST FUEL PRESSURE....14288
METHOD FOR TESTING FUEL PRESSURE....14288
TEST FUEL RETURN RATE AND LEAKAGE....14290
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE....14291
BLEEDING AIR FROM FUEL SYSTEM....14294
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM....14295
TEST FUEL CIRCUIT FOR LEAKAGE....14296
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE....14296
HANDLE CYLINDER CUT-OUT MODE OPERATION....14298
HANDLE NO-INJECTION CRANKING OPERATION....14299
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE....14300
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE....14300
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS....14301
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS....14301
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS....14302
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS....14302
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION....14303
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION....14303
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION....14303
TEST ALTERNATOR BELT....14305
METHOD FOR TESTING ALTERNATOR BELT....14305
TEST AUTOMATIC TENSIONER....14307
METHOD FOR TESTING AUTOMATIC TENSIONER....14307
CLEAN FUEL DOSER....14310
METHOD FOR CLEANING FUEL DOSER....14310
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER....14312
METHOD FOR WRITING INJECTOR COMPENSATION VALUE....14312
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER....14319
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER....14319
TEST SCR RELATED FUNCTIONS....14320
TEST AdBlue/DEF PUMP RAISED PRESSURE....14324
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR....14327
TEST AdBlue/DEF LINE HEATER RELAY 1....14332
TEST AdBlue/DEF LINE HEATER RELAY 2....14336
TEST AdBlue/DEF PUMP HEATER RELAY....14340
TEST AdBlue/DEF TANK HEATER VALVE....14344
TEST SCR NOx REMOVAL EFFICIENCY....14348
CLEAN AdBlue/DEF TANK....14352
METHOD FOR CLEANING AdBlue/DEF TANK....14352
POWER TRAIN....14356
TEST AND ADJUST POWER TRAIN OIL PRESSURE....14356
METHOD FOR TESTING POWER TRAIN OIL PRESSURE....14358
METHOD FOR ADJUSTING POWER TRAIN OIL PRESSURE....14375
ADJUST TRANSMISSION INPUT SPEED SENSOR....14377
METHOD FOR ADJUSTING TRANSMISSION INPUT SPEED SENSOR....14377
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR....14379
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR....14379
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT....14380
METHOD FOR FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT....14380
MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE....14383
METHOD FOR MOVING DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE....14384
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE....14387
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE....14387
STEERING SYSTEM....14388
TEST STEERING WHEEL....14388
METHOD FOR TESTING STEERING WHEEL....14388
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE....14390
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE....14390
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE....14393
BLEED AIR FROM STEERING CYLINDER CIRCUIT....14394
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT....14394
TEST AND ADJUST STEERING STOP VALVE....14396
METHOD FOR TESTING STEERING STOP VALVE....14396
METHOD FOR ADJUSTING STEERING STOP VALVE....14396
BRAKE SYSTEM....14397
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT....14397
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT....14397
TEST WHEEL BRAKE OIL PRESSURE....14398
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE....14398
TEST AND ADJUST ACCUMULATOR CHARGE PRESSURE....14401
METHOD FOR TESTING ACCUMULATOR CHARGE PRESSURE....14401
METHOD FOR ADJUSTING ACCUMULATOR CHARGE PRESSURE....14402
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE....14403
METHOD FOR TESTING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE....14403
METHOD FOR CHARGING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE....14405
TEST BRAKING PERFORMANCE....14408
METHOD FOR TESTING BRAKING PERFORMANCE....14408
TEST BRAKE PEDAL....14409
METHOD FOR TESTING BRAKE PEDAL....14409
BLEED AIR FROM BRAKE CIRCUIT....14410
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT....14410
TEST AND ADJUST BRAKE PEDAL AND LINKAGE....14413
METHOD FOR TESTING BRAKE PEDAL AND LINKAGE....14413
METHOD FOR ADJUSTING BRAKE PEDAL AND LINKAGE....14413
TEST LOWERING OF WHEEL BRAKE PRESSURE....14414
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE....14415
TEST WEAR OF WHEEL BRAKE DISC....14417
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC....14417
TEST PARKING BRAKE OIL PRESSURE....14419
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE....14419
TEST PARKING BRAKE PERFORMANCE....14421
METHOD FOR TESTING PARKING BRAKE PERFORMANCE....14421
RELEASE PARKING BRAKE MANUALLY....14422
METHOD FOR RELEASING PARKING BRAKE MANUALLY....14422
TEST WEAR AMOUNT OF PARKING BRAKE DISC....14424
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC....14424
HYDRAULIC SYSTEM....14426
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT....14426
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT....14426
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE....14428
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE....14428
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE....14433
TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE....14434
METHOD FOR TESTING WORK EQUIPMENT EPC OIL PRESSURE....14434
METHOD FOR ADJUSTING WORK EQUIPMENT EPC OIL PRESSURE....14437
BLEED AIR FROM WORK EQUIPMENT CIRCUIT....14439
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT....14439
TEST COOLING FAN SPEED....14440
METHOD FOR TESTING COOLING FAN SPEED....14440
TEST COOLING FAN CIRCUIT OIL PRESSURE....14442
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE....14442
BLEED AIR FROM COOLING FAN CIRCUIT....14445
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT....14445
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS....14447
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE....14447
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS....14449
WORK EQUIPMENT....14453
TEST AND ADJUST BUCKET POTENTIOMETER LEVER....14453
METHOD FOR TESTING BUCKET POSITIONER DETECTION LEVER....14453
METHOD FOR ADJUSTING BUCKET POSITIONER DETECTION LEVER....14453
TEST AND ADJUST BOOM POTENTIOMETER LEVER....14455
METHOD FOR TESTING BOOM POSITION DETECTION LEVER....14455
METHOD FOR ADJUSTING BOOM POSITION DETECTION LEVER....14455
CAB AND ITS ATTACHMENTS....14456
TEST DIRECTIONAL LEVER....14456
METHOD FOR TESTING DIRECTIONAL LEVER....14456
TEST WORK EQUIPMENT CONTROL LEVER....14457
METHOD FOR TESTING WORK EQUIPMENT CONTROL LEVER....14457
ELECTRICAL SYSTEM....14460
SET AND ADJUST EACH EQUIPMENT....14460
PREPARATION FOR TRANSMISSION ECMV CURRENT ADJUSTMENT....14462
METHOD FOR ADJUSTING TRANSMISSION ECMV CURRENT....14464
METHOD FOR SETTING AND RESETTING TRANSMISSION INITIAL LEARNING....14467
SET AND OPERATE MACHINE MONITOR....14472
OPERATOR MODE....14476
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN....14476
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN....14476
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)....14477
CHECKING FUNCTION OF SERVICE METER AND ODOMETER....14478
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD....14478
SERVICE MODE....14482
METHOD FOR OPERATING SERVICE MODE....14482
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION....14485
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION....14492
ABNORMALITY RECORD MENU....14508
METHOD FOR CONFIRMING MAINTENANCE RECORD....14513
METHOD FOR OPERATING MAINTENANCE MODE SETTING....14515
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING....14520
DEFAULT MENU....14522
DIAGNOSTIC TESTS MENU....14537
ADJUSTMENT MENU....14549
METHOD FOR PERFORMING NO-INJECTION CRANKING....14582
KOMTRAX SETTINGS MENU....14585
METHOD FOR DISPLAYING SERVICE MESSAGE....14587
METHOD FOR STARTING UP KOMTRAX TERMINAL....14589
ADJUST REARVIEW CAMERA ANGLE....14594
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE....14594
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER....14596
HANDLE BATTERY DISCONNECT SWITCH....14597
TEST DIODES....14598
METHOD FOR TESTING DIODE USING DIGITAL TESTER....14598
METHOD FOR TESTING DIODE USING ANALOG TESTER....14598
AUTO-GREASING DEVICE....14599
BLEED THE AIR OF AUTO-GREASING SYSTEM....14599
METHOD FOR BLEEDING THE AIR OF AUTO-GREASING SYSTEM....14599
CORREPONDENCE IN CASE OF GREASE LEAKAGE FROM OVER PRESSURE PROTECTION VALVE....14602
CORREPONDING METHOD FOR GREASE LEAKAGE FROM OVER PRESSURE PROTECTION VALVE....14602
CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES....14603
METHOD FOR CHANGING THE LUBRICATION TIME AND LUBRICATION INTERVAL TIMES....14604
Pm CLINIC....14606
Pm CLINIC SERVICE....14606
Pm CLINIC CHECK SHEET....14609
40 TROUBLESHOOTING....14620
CONTENTS....14621
ABBREVIATION LIST....14634
RELATED INFORMATION ON TROUBLESHOOTING....14640
GENERAL TROUBLESHOOTING POINTS....14640
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM....14641
SEQUENCE OF EVENTS IN TROUBLESHOOTING....14653
CHECKS BEFORE TROUBLESHOOTING....14655
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING....14657
WALK-AROUND CHECK....14657
TESTING IN ACCORDANCE WITH TESTING PROCEDURE....14659
CHECK FUEL LEVEL AND TYPE....14659
CHECK IMPURE INGREDIENT IN FUEL....14659
CHECK AdBule/DEF LEVEL AND TYPE....14660
CHECK FUEL PREFILTER....14660
CHECK MAIN FILTER....14662
OIL PAN - CHECK ENGINE OIL LEVEL AND TYPE....14663
CHECK COOLANT LEVEL (RESERVOIR TANK)....14663
CHECK CLOGGING OF AIR CLEANER....14664
OUTER ELEMENT - CLEAN....14665
REPLACE ELEMENT....14667
CHECK HYDRAULIC OIL LEVEL....14668
CHECK HYDRAULIC OIL STRAINER....14669
CHECK HYDRAULIC FILTER....14670
CHECK OIL LEVEL IN TRANSMISSION CASE....14671
CHECK OIL LEVEL IN FRONT AXLE CASE....14673
CHECK OIL LEVEL IN REAR AXLE CASE....14674
BLEED AIR FROM FUEL SYSTEM....14674
BLEED AIR FROM HYDRAULIC SYSTEM....14674
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod....14674
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION....14680
PROCEDURE FOR TESTING AND TROUBLESHOOTING....14692
SYMPTOM AND TROUBLESHOOTING NUMBERS....14694
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE....14699
CONNECTORS LIST AND LAYOUT....14701
CONNECTOR CONTACT IDENTIFICATION....14721
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE....14761
FUSE LOCATION TABLE....14767
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)....14771
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR....14775
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT....14777
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])....14783
FAILURE CODES TABLE....14785
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)....14809
FAILURE CODE [1500L0]....14809
FAILURE CODE [15SAL1]....14810
FAILURE CODE [15SALH]....14812
FAILURE CODE [15SBL1]....14814
FAILURE CODE [15SBLH]....14816
FAILURE CODE [15SEL1]....14818
FAILURE CODE [15SELH]....14820
FAILURE CODE [15SFL1]....14822
FAILURE CODE [15SFLH]....14824
FAILURE CODE [15SGL1]....14826
FAILURE CODE [15SGLH]....14828
FAILURE CODE [15SHL1]....14830
FAILURE CODE [15SHLH]....14832
FAILURE CODE [2F00MA]....14835
FAILURE CODE [2F00MB]....14839
FAILURE CODE [2G42ZG]....14842
FAILURE CODE [2G43ZG]....14844
FAILURE CODE [879AKA]....14846
FAILURE CODE [879AKB]....14848
FAILURE CODE [879BKA]....14850
FAILURE CODE [879BKB]....14852
FAILURE CODE [879CKA]....14854
FAILURE CODE [879CKB]....14856
FAILURE CODE [879DKZ]....14858
FAILURE CODE [879EMC]....14860
FAILURE CODE [879FMC]....14863
FAILURE CODE [989A00]....14866
FAILURE CODE [989L00]....14867
FAILURE CODE [989M00]....14868
FAILURE CODE [989N00]....14869
FAILURE CODE [A1U0N3]....14870
FAILURE CODE [A1U0N4]....14872
FAILURE CODE [AA10NX]....14874
FAILURE CODE [AB00KE]....14876
FAILURE CODE [AB00KY]....14878
FAILURE CODE [AQ10N3]....14880
FAILURE CODE [AS00N3]....14882
FAILURE CODE [AS00R2]....14884
FAILURE CODE [AS00R3]....14885
FAILURE CODE [AS00R4]....14886
FAILURE CODE [AS00R5]....14887
FAILURE CODE [AS00R6]....14888
FAILURE CODE [AS00ZK]....14889
FAILURE CODE [AS10KM]....14890
FAILURE CODE [AS10NR]....14891
FAILURE CODE [AS10NT]....14892
FAILURE CODE [B@BAZG]....14893
FAILURE CODE [B@BAZK]....14894
FAILURE CODE [B@BCNS]....14896
FAILURE CODE [B@BCZK]....14897
FAILURE CODE [B@C7NS]....14899
FAILURE CODE [B@CENS]....14901
FAILURE CODE [B@HANS]....14902
FAILURE CODE [CA115]....14903
FAILURE CODE [CA122]....14904
FAILURE CODE [CA123]....14906
FAILURE CODE [CA131]....14908
FAILURE CODE [CA132]....14910
FAILURE CODE [CA135]....14913
FAILURE CODE [CA141]....14915
FAILURE CODE [CA144]....14917
FAILURE CODE [CA145]....14919
FAILURE CODE [CA153]....14921
FAILURE CODE [CA154]....14924
FAILURE CODE [CA187]....14927
FAILURE CODE [CA221]....14929
FAILURE CODE [CA222]....14931
FAILURE CODE [CA227]....14933
FAILURE CODE [CA234]....14934
FAILURE CODE [CA238]....14935
FAILURE CODE [CA239]....14937
FAILURE CODE [CA249]....14939
FAILURE CODE [CA256]....14941
FAILURE CODE [CA271]....14943
FAILURE CODE [CA272]....14945
FAILURE CODE [CA273]....14946
FAILURE CODE [CA274]....14948
FAILURE CODE [CA322]....14949
FAILURE CODE [CA323]....14951
FAILURE CODE [CA324]....14953
FAILURE CODE [CA325]....14955
FAILURE CODE [CA331]....14957
FAILURE CODE [CA332]....14959
FAILURE CODE [CA343]....14961
FAILURE CODE [CA351]....14962
FAILURE CODE [CA352]....14963
FAILURE CODE [CA356]....14966
FAILURE CODE [CA357]....14968
FAILURE CODE [CA386]....14970
FAILURE CODE [CA431]....14971
FAILURE CODE [CA432]....14974
FAILURE CODE [CA441]....14978
FAILURE CODE [CA442]....14980
FAILURE CODE [CA449]....14981
FAILURE CODE [CA451]....14982
FAILURE CODE [CA452]....14984
FAILURE CODE [CA515]....14986
FAILURE CODE [CA516]....14988
FAILURE CODE [CA553]....14990
FAILURE CODE [CA555]....14991
FAILURE CODE [CA556]....14992
FAILURE CODE [CA559]....14993
FAILURE CODE [CA595]....14998
FAILURE CODE [CA687]....14999
FAILURE CODE [CA689]....15001
FAILURE CODE [CA691]....15003
FAILURE CODE [CA692]....15005
FAILURE CODE [CA697]....15007
FAILURE CODE [CA698]....15008
FAILURE CODE [CA731]....15009
FAILURE CODE [CA778]....15010
FAILURE CODE [CA1117]....15013
FAILURE CODE [CA1664]....15014
FAILURE CODE [CA1669]....15017
FAILURE CODE [CA1673]....15018
FAILURE CODE [CA1677]....15019
FAILURE CODE [CA1678]....15020
FAILURE CODE [CA1682]....15021
FAILURE CODE [CA1683]....15023
FAILURE CODE [CA1684]....15025
FAILURE CODE [CA1686]....15027
FAILURE CODE [CA1691]....15028
FAILURE CODE [CA1694]....15031
FAILURE CODE [CA1695]....15033
FAILURE CODE [CA1696]....15034
FAILURE CODE [CA1712]....15036
FAILURE CODE [CA1713]....15039
FAILURE CODE [CA1714]....15041
FAILURE CODE [CA1715]....15042
FAILURE CODE [CA1776]....15043
FAILURE CODE [CA1777]....15046
FAILURE CODE [CA1843]....15049
FAILURE CODE [CA1844]....15051
FAILURE CODE [CA1879]....15054
FAILURE CODE [CA1881]....15057
FAILURE CODE [CA1883]....15059
FAILURE CODE [CA1885]....15063
FAILURE CODE [CA1887]....15065
FAILURE CODE [CA1921]....15067
FAILURE CODE [CA1922]....15070
FAILURE CODE [CA1923]....15075
FAILURE CODE [CA1924]....15077
FAILURE CODE [CA1925]....15079
FAILURE CODE [CA1927]....15081
FAILURE CODE [CA1928]....15083
FAILURE CODE [CA1942]....15085
FAILURE CODE [CA1963]....15086
FAILURE CODE [CA1977]....15090
FAILURE CODE [CA1993]....15093
FAILURE CODE [CA2185]....15096
FAILURE CODE [CA2186]....15098
FAILURE CODE [CA2249]....15100
FAILURE CODE [CA2265]....15101
FAILURE CODE [CA2266]....15103
FAILURE CODE [CA2271]....15106
FAILURE CODE [CA2272]....15108
FAILURE CODE [CA2349]....15110
FAILURE CODE [CA2353]....15112
FAILURE CODE [CA2357]....15114
FAILURE CODE [CA2381]....15115
FAILURE CODE [CA2382]....15117
FAILURE CODE [CA2383]....15119
FAILURE CODE [CA2386]....15121
FAILURE CODE [CA2387]....15123
FAILURE CODE [CA2555]....15124
FAILURE CODE [CA2556]....15126
FAILURE CODE [CA2637]....15128
FAILURE CODE [CA2639]....15130
FAILURE CODE [CA2732]....15133
FAILURE CODE [CA2733]....15135
FAILURE CODE [CA2741]....15137
FAILURE CODE [CA2765]....15138
FAILURE CODE [CA2771]....15139
FAILURE CODE [CA2777]....15145
FAILURE CODE [CA2878]....15148
FAILURE CODE [CA2881]....15151
FAILURE CODE [CA2976]....15154
FAILURE CODE [CA3133]....15156
FAILURE CODE [CA3134]....15158
FAILURE CODE [CA3135]....15160
FAILURE CODE [CA3142]....15164
FAILURE CODE [CA3143]....15165
FAILURE CODE [CA3144]....15166
FAILURE CODE [CA3146]....15169
FAILURE CODE [CA3147]....15170
FAILURE CODE [CA3148]....15171
FAILURE CODE [CA3151]....15173
FAILURE CODE [CA3165]....15179
FAILURE CODE [CA3167]....15181
FAILURE CODE [CA3229]....15184
FAILURE CODE [CA3231]....15186
FAILURE CODE [CA3232]....15188
FAILURE CODE [CA3235]....15192
FAILURE CODE [CA3239]....15194
FAILURE CODE [CA3241]....15197
FAILURE CODE [CA3242]....15200
FAILURE CODE [CA3251]....15203
FAILURE CODE [CA3253]....15205
FAILURE CODE [CA3254]....15208
FAILURE CODE [CA3255]....15211
FAILURE CODE [CA3256]....15215
FAILURE CODE [CA3311]....15217
FAILURE CODE [CA3312]....15219
FAILURE CODE [CA3313]....15222
FAILURE CODE [CA3314]....15223
FAILURE CODE [CA3315]....15224
FAILURE CODE [CA3316]....15227
FAILURE CODE [CA3317]....15228
FAILURE CODE [CA3318]....15229
FAILURE CODE [CA3319]....15232
FAILURE CODE [CA3321]....15233
FAILURE CODE [CA3322]....15235
FAILURE CODE [CA3419]....15238
FAILURE CODE [CA3421]....15240
FAILURE CODE [CA3497]....15242
FAILURE CODE [CA3498]....15243
FAILURE CODE [CA3543]....15244
FAILURE CODE [CA3545]....15251
FAILURE CODE [CA3547]....15253
FAILURE CODE [CA3558]....15254
FAILURE CODE [CA3559]....15256
FAILURE CODE [CA3562]....15258
FAILURE CODE [CA3563]....15260
FAILURE CODE [CA3567]....15263
FAILURE CODE [CA3568]....15267
FAILURE CODE [CA3571]....15271
FAILURE CODE [CA3572]....15273
FAILURE CODE [CA3574]....15275
FAILURE CODE [CA3575]....15277
FAILURE CODE [CA3577]....15279
FAILURE CODE [CA3578]....15281
FAILURE CODE [CA3582]....15283
FAILURE CODE [CA3583]....15289
FAILURE CODE [CA3596]....15291
FAILURE CODE [CA3649]....15293
FAILURE CODE [CA3681]....15295
FAILURE CODE [CA3682]....15300
FAILURE CODE [CA3713]....15306
FAILURE CODE [CA3717]....15309
FAILURE CODE [CA3718]....15310
FAILURE CODE [CA3725]....15311
FAILURE CODE [CA3748]....15314
FAILURE CODE [CA3751]....15317
FAILURE CODE [CA3755]....15319
FAILURE CODE [CA3866]....15321
FAILURE CODE [CA3867]....15324
FAILURE CODE [CA3868]....15327
FAILURE CODE [CA3899]....15331
FAILURE CODE [CA3911]....15333
FAILURE CODE [CA3912]....15337
FAILURE CODE [CA3932]....15339
FAILURE CODE [CA3933]....15341
FAILURE CODE [CA3934]....15343
FAILURE CODE [CA3935]....15346
FAILURE CODE [CA3936]....15348
FAILURE CODE [CA4151]....15350
FAILURE CODE [CA4152]....15354
FAILURE CODE [CA4155]....15358
FAILURE CODE [CA4156]....15361
FAILURE CODE [CA4157]....15364
FAILURE CODE [CA4158]....15366
FAILURE CODE [CA4159]....15367
FAILURE CODE [CA4161]....15368
FAILURE CODE [CA4162]....15371
FAILURE CODE [CA4163]....15374
FAILURE CODE [CA4164]....15376
FAILURE CODE [CA4165]....15378
FAILURE CODE [CA4166]....15381
FAILURE CODE [CA4168]....15383
FAILURE CODE [CA4169]....15386
FAILURE CODE [CA4171]....15388
FAILURE CODE [CA4249]....15391
FAILURE CODE [CA4251]....15393
FAILURE CODE [CA4259]....15395
FAILURE CODE [CA4261]....15398
FAILURE CODE [CA4277]....15401
FAILURE CODE [CA4281]....15404
FAILURE CODE [CA4459]....15407
FAILURE CODE [CA4461]....15410
FAILURE CODE [CA4658]....15413
FAILURE CODE [CA4731]....15417
FAILURE CODE [CA4732]....15418
FAILURE CODE [CA4739]....15419
FAILURE CODE [CA4768]....15420
FAILURE CODE [CA4769]....15422
FAILURE CODE [CA4842]....15425
FAILURE CODE [CA4952]....15428
FAILURE CODE [CA5115]....15430
FAILURE CODE [CA5179]....15433
FAILURE CODE [CA5181]....15435
FAILURE CODE [CA5383]....15437
FAILURE CODE [D150KA]....15439
FAILURE CODE [D150KB]....15441
FAILURE CODE [D150KY]....15443
FAILURE CODE [D160KA]....15445
FAILURE CODE [D160KB]....15447
FAILURE CODE [D160KY]....15449
FAILURE CODE [D191KA]....15451
FAILURE CODE [D191KB]....15454
FAILURE CODE [D191KY]....15457
FAILURE CODE [D192KA]....15459
FAILURE CODE [D192KB]....15461
FAILURE CODE [D192KY]....15463
FAILURE CODE [D19JKZ]....15464
FAILURE CODE [D1E6KA]....15466
FAILURE CODE [D1E6KB]....15468
FAILURE CODE [D1E6KY]....15470
FAILURE CODE [D5ZHKA]....15472
FAILURE CODE [D5ZHKB]....15474
FAILURE CODE [D5ZHKZ]....15476
FAILURE CODE [D5ZHL6]....15479
FAILURE CODE [D811MC]....15481
FAILURE CODE [D862KA]....15482
FAILURE CODE [D8ALKA]....15483
FAILURE CODE [D8ALKB]....15485
FAILURE CODE [D8AQK4]....15487
FAILURE CODE [D8AQKR]....15488
FAILURE CODE [DAF0KT]....15490
FAILURE CODE [DAF0MB]....15491
FAILURE CODE [DAF0MC]....15492
FAILURE CODE [DAF3KK]....15493
FAILURE CODE [DAF8KB]....15495
FAILURE CODE [DAFDKB]....15497
FAILURE CODE [DAFGMC]....15499
FAILURE CODE [DAFLKA]....15500
FAILURE CODE [DAFLKB]....15502
FAILURE CODE [DAFQKR]....15504
FAILURE CODE [DAQ0KK]....15505
FAILURE CODE [DAQ0KT]....15508
FAILURE CODE [DAQ0MC]....15509
FAILURE CODE [DAQ1KA]....15510
FAILURE CODE [DAQ2KK]....15512
FAILURE CODE [DAQ4KB]....15515
FAILURE CODE [DAQ9KQ]....15517
FAILURE CODE [DAQLKA]....15518
FAILURE CODE [DAQLKB]....15520
FAILURE CODE [DAQQKR]....15522
FAILURE CODE [DAQRKR]....15523
FAILURE CODE [DAQRMA]....15524
FAILURE CODE [DAZ9KQ]....15525
FAILURE CODE [DAZQKR]....15526
FAILURE CODE [DB2QKR]....15527
FAILURE CODE [DB2RKR]....15532
FAILURE CODE [DB90KK]....15538
FAILURE CODE [DB90KT]....15541
FAILURE CODE [DB90MC]....15542
FAILURE CODE [DB91KA]....15543
FAILURE CODE [DB92KK]....15545
FAILURE CODE [DB95KX]....15548
FAILURE CODE [DB96KX]....15551
FAILURE CODE [DB99KQ]....15553
FAILURE CODE [DB9LKA]....15554
FAILURE CODE [DB9LKB]....15556
FAILURE CODE [DB9QKR]....15558
FAILURE CODE [DB9RKR]....15559
FAILURE CODE [DB9RMA]....15560
FAILURE CODE [DBE5KX]....15561
FAILURE CODE [DBE6KX]....15563
FAILURE CODE [DD1ALD]....15565
FAILURE CODE [DDAAL6]....15567
FAILURE CODE [DDB6L4]....15569
FAILURE CODE [DDD1LD]....15572
FAILURE CODE [DDK3KA]....15574
FAILURE CODE [DDK3KB]....15577
FAILURE CODE [DDK6KA]....15580
FAILURE CODE [DDK6KB]....15583
FAILURE CODE [DDKLKA]....15586
FAILURE CODE [DDKLKB]....15589
FAILURE CODE [DDNRKY]....15591
FAILURE CODE [DDT0L4]....15593
FAILURE CODE [DDT4LD]....15595
FAILURE CODE [DDT9LD]....15597
FAILURE CODE [DDTALD]....15599
FAILURE CODE [DDW9LD]....15601
FAILURE CODE [DDWLLD]....15603
FAILURE CODE [DF10KA]....15605
FAILURE CODE [DF10KB]....15608
FAILURE CODE [DGF1KA]....15611
FAILURE CODE [DGF1KB]....15613
FAILURE CODE [DGH2KX]....15615
FAILURE CODE [DGR2KB]....15617
FAILURE CODE [DGR2KZ]....15619
FAILURE CODE [DGT1KA]....15621
FAILURE CODE [DGT1KB]....15623
FAILURE CODE [DH21KA]....15625
FAILURE CODE [DH21KB]....15628
FAILURE CODE [DHA4KA]....15630
FAILURE CODE [DHAAMA]....15632
FAILURE CODE [DHACMA]....15634
FAILURE CODE [DHPCKX]....15636
FAILURE CODE [DHPDKX]....15639
FAILURE CODE [DHT1KX]....15642
FAILURE CODE [DHT5KX]....15645
FAILURE CODE [DHT7KX]....15648
FAILURE CODE [DHT8KA]....15651
FAILURE CODE [DHT8KB]....15654
FAILURE CODE [DHT8ZG]....15656
FAILURE CODE [DHUDKA]....15657
FAILURE CODE [DHUDKB]....15660
FAILURE CODE [DJF1KA]....15662
FAILURE CODE [DK55KA]....15664
FAILURE CODE [DK55KY]....15667
FAILURE CODE [DK55L5]....15669
FAILURE CODE [DK59KA]....15670
FAILURE CODE [DK59KY]....15674
FAILURE CODE [DK59L8]....15678
FAILURE CODE [DK5AKA]....15683
FAILURE CODE [DK5AKY]....15687
FAILURE CODE [DK5BKA]....15691
FAILURE CODE [DK5BKY]....15695
FAILURE CODE [DK5BL8]....15699
FAILURE CODE [DK5CKA]....15704
FAILURE CODE [DK5CKY]....15708
FAILURE CODE [DK5DKA]....15712
FAILURE CODE [DK5DKY]....15715
FAILURE CODE [DK5DL8]....15718
FAILURE CODE [DK5EKA]....15722
FAILURE CODE [DK5EKY]....15725
FAILURE CODE [DKA0KA]....15728
FAILURE CODE [DKA0KY]....15731
FAILURE CODE [DKA0L0]....15734
FAILURE CODE [DKA1KA]....15737
FAILURE CODE [DKA1KY]....15740
FAILURE CODE [DLF1KA]....15743
FAILURE CODE [DLF1LC]....15745
FAILURE CODE [DLM3KA]....15747
FAILURE CODE [DLM3LC]....15749
FAILURE CODE [DLT3KA]....15751
FAILURE CODE [DLT3LC]....15753
FAILURE CODE [DPQ1KR]....15755
FAILURE CODE [DPQ2KR]....15758
FAILURE CODE [DPQ3KR]....15761
FAILURE CODE [DSJ0KR]....15764
FAILURE CODE [DT20KB]....15767
FAILURE CODE [DT22KB]....15769
FAILURE CODE [DT23KB]....15771
FAILURE CODE [DV00KB]....15773
FAILURE CODE [DW4PKA]....15775
FAILURE CODE [DW4PKB]....15777
FAILURE CODE [DW4PKY]....15779
FAILURE CODE [DW4QKA]....15781
FAILURE CODE [DW4QKB]....15783
FAILURE CODE [DW4QKY]....15785
FAILURE CODE [DW4RKA]....15787
FAILURE CODE [DW4RKB]....15789
FAILURE CODE [DW4RKY]....15791
FAILURE CODE [DW4SKA]....15793
FAILURE CODE [DW4SKB]....15795
FAILURE CODE [DW4SKY]....15797
FAILURE CODE [DW7BKA]....15799
FAILURE CODE [DW7BKB]....15801
FAILURE CODE [DW7BKY]....15803
FAILURE CODE [DWM1KA]....15805
FAILURE CODE [DWM1KB]....15807
FAILURE CODE [DWM1KY]....15809
FAILURE CODE [DWN6KA]....15811
FAILURE CODE [DWN6KB]....15813
FAILURE CODE [DWN6KY]....15815
FAILURE CODE [DWN8KA]....15817
FAILURE CODE [DWN8KB]....15819
FAILURE CODE [DWN8KY]....15821
FAILURE CODE [DX16KA]....15823
FAILURE CODE [DX16KB]....15825
FAILURE CODE [DX16KY]....15827
FAILURE CODE [DXA1KA]....15829
FAILURE CODE [DXA1KB]....15831
FAILURE CODE [DXA1KY]....15833
FAILURE CODE [DXANKA]....15835
FAILURE CODE [DXANKB]....15837
FAILURE CODE [DXANKY]....15839
FAILURE CODE [DXH1KA]....15841
FAILURE CODE [DXH1KB]....15843
FAILURE CODE [DXH1KY]....15845
FAILURE CODE [DXH4KA]....15847
FAILURE CODE [DXH4KB]....15849
FAILURE CODE [DXH4KY]....15851
FAILURE CODE [DXH5KA]....15853
FAILURE CODE [DXH5KB]....15855
FAILURE CODE [DXH5KY]....15857
FAILURE CODE [DXH6KA]....15859
FAILURE CODE [DXH6KB]....15861
FAILURE CODE [DXH6KY]....15863
FAILURE CODE [DXH7KA]....15865
FAILURE CODE [DXH7KB]....15867
FAILURE CODE [DXH7KY]....15869
FAILURE CODE [DXH8KA]....15871
FAILURE CODE [DXH8KB]....15873
FAILURE CODE [DXH8KY]....15875
FAILURE CODE [DXHHKA]....15877
FAILURE CODE [DXHHKB]....15879
FAILURE CODE [DXHHKY]....15881
FAILURE CODE [DXHJKA]....15883
FAILURE CODE [DXHJKB]....15885
FAILURE CODE [DXHJKY]....15887
FAILURE CODE [DXHKKA]....15889
FAILURE CODE [DXHKKB]....15891
FAILURE CODE [DXHKKY]....15893
FAILURE CODE [DY30MA]....15895
FAILURE CODE [DY30MC]....15899
FAILURE CODE [DY30ME]....15904
FAILURE CODE [LA00L3]....15906
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)....15907
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)....15907
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK....15914
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK....15917
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP....15920
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING....15922
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING....15925
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)....15928
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY....15931
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL....15934
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL....15937
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL....15941
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY....15943
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION....15946
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL....15949
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY....15952
E-16 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS....15953
E-17 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY....15956
E-18 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED....15959
E-19 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL....15963
E-20 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP....15965
E-21 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP....15967
E-22 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION....15969
E-23 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP....15973
E-24 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP....15974
E-25 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL....15975
E-26 TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP....15977
E-27 INDICATION OF HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT....15978
E-28 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL....15980
E-29 ALARM BUZZER DOES NOT SOUND....15981
E-30 ALARM BUZZER DOES NOT STOP SOUNDING....15983
E-31 KICKDOWN DOES NOT WORK WHEN KICKDOWN SWITCH IS TURNED ON....15984
E-32 HOLD SWITCH DOES NOT WORK WHEN IT IS PRESSED....15986
E-33 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED....15988
E-34 TRANSMISSION CUT-OFF MODE IS NOT SELECTED OR NOT RELEASED....15992
E-35 TRANSMISSION CUT-OFF SETTING CANNOT BE RELEASED....15994
E-36 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED....15996
E-37 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE NORMALLY WHEN ENGINE POWER MODE SELECTOR SWITCH IS OPERATED....15998
E-38 FLOW OF LOADER PUMP DOES NOT INCREASE FROM THE MINIMUM RATE....16000
E-39 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED....16001
E-40 HORN DOES NOT SOUND....16003
E-41 HORN DOES NOT STOP SOUNDING....16006
E-42 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS....16008
E-43 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT....16010
E-44 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT....16014
E-45 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT....16018
E-46 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT....16020
E-47 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT....16022
E-48 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)....16027
E-49 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT....16032
E-50 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)....16036
E-51 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT....16041
E-52 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT....16044
E-53 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT....16047
E-54 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED....16051
E-55 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT....16055
E-56 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND....16058
E-57 FRONT WIPER DOES NOT OPERATE....16060
E-58 REAR WIPER DOES NOT OPERATE....16064
E-59 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY....16067
E-60 WINDOW WASHER DOES NOT OPERATE....16070
E-61 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY....16073
E-62 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP....16074
E-63 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP....16076
E-64 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP....16077
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)....16079
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)....16079
FAILURE MODE AND CAUSE TABLE....16080
H-1 MACHINE DOES NOT START....16094
H-2 LOCKUP IS NOT RELEASED....16097
H-3 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE....16098
H-4 TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADABILITY IS LOW, OR GEAR SPEED DOES NOT SHIFT....16099
H-5 LARGE SHOCK IS MADE WHEN MACHINE MOVES OFF OR GEAR IS SHIFTED....16102
H-6 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED....16105
H-7 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH....16108
H-8 MACHINE DOES NOT TURN (FOR STEERING WHEEL SPEC)....16111
H-9 TURNING RESPONSE IS POOR (FOR STEERING WHEEL SPEC)....16113
H-10 STEERING WHEEL IS HEAVY TO OPERATE....16115
H-11 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (FOR STEERING WHEEL SPEC)....16116
H-12 TURNING RADIUS DIFFERS BETWEEN RIGHT AND LEFT TURNS....16118
H-13 WHEEL BRAKES DO NOT WORK OR ARE WEAK....16119
H-14 WHEEL BRAKES ARE NOT RELEASED OR DRAG....16121
H-15 PARKING BRAKE DOES NOT WORK OR IT IS WEAK....16122
H-16 PARKING BRAKE IS NOT RELEASED OR DRAGS....16123
H-17 BOOM DOES NOT RISE....16125
H-18 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE....16127
H-19 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT....16129
H-20 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND....16130
H-21 HYDRAULIC DRIFT OF BOOM IS LARGE....16132
H-22 BOOM MOVES UP AND DOWN DURING OPERATION....16133
H-23 BUCKET DOES NOT TILT BACK....16134
H-24 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE....16136
H-25 BUCKET DECELERATES DURING TILT-BACK OPERATION....16138
H-26 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND....16139
H-27 HYDRAULIC DRIFT OF BUCKET IS LARGE....16141
H-28 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD)....16142
H-29 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE....16143
H-30 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS....16144
H-31 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS....16145
H-32 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES....16148
H-33 E.C.S.S. (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES....16149
H-34 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)....16150
H-35 UNUSUAL NOISE IS HEARD FROM AROUND FAN....16152
TROUBLESHOOTING OF ENGINE (S-MODE)....16153
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)....16153
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION....16154
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT....16155
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)....16156
S-4 ENGINE STARTABILITY IS POOR....16157
S-5 ENGINE DOES NOT PICK UP SMOOTHLY....16159
S-6 ENGINE STOPS DURING OPERATION....16161
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE....16163
S-8 ENGINE LACKS POWER....16164
S-9 KDPF GETS CLOGGED IN A SHORT TIME....16166
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE....16168
S-11 OIL BECOMES CONTAMINATED QUICKLY....16169
S-12 FUEL CONSUMPTION IS EXCESSIVE....16170
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)....16171
S-14 OIL PRESSURE DROPS....16172
S-15 FUEL MIXES INTO ENGINE OIL....16174
S-16 WATER MIXES INTO ENGINE OIL (MILKY)....16175
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)....16176
S-18 UNUSUAL NOISE IS HEARD....16177
S-19 VIBRATION IS EXCESSIVE....16178
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT....16179
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY....16180
S-22 ACTIVE REGENERATION TAKES TIME....16182
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION....16184
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE....16185
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)....16187
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)....16188
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM....16189
OUTLINE OF FAILURE DISPLAY....16189
TROUBLESHOOTING FOR FCS....16190
TROUBLESHOOTING FOR AUTO-GREASING PUMP....16191
REPLACEMENT OF PUMP ELEMENT....16194
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM....16195
REPLACEMENT OF AUTO-GREASING CONTROLLER....16197
PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING....16198
50 DISASSEMBLY AND ASSEMBLY....16200
CONTENTS....16201
ABBREVIATION LIST....16206
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY....16212
HOW TO READ THIS MANUAL....16212
COATING MATERIALS LIST....16214
SPECIAL TOOLS LIST....16219
SKETCHES OF SPECIAL TOOLS....16239
ENGINE AND COOLING SYSTEM....16262
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY....16262
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY....16262
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY....16266
REMOVE AND INSTALL INJECTOR ASSEMBLY....16272
METHOD FOR REMOVING INJECTOR ASSEMBLY....16272
METHOD FOR INSTALLING INJECTOR ASSEMBLY....16276
REMOVE AND INSTALL FUEL DOSER ASSEMBLY....16284
METHOD FOR REMOVING FUEL DOSER ASSEMBLY....16284
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY....16285
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY....16288
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY....16288
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY....16299
REMOVE AND INSTALL EGR VALVE ASSEMBLY....16316
METHOD FOR REMOVING EGR VALVE ASSEMBLY....16316
METHOD FOR INSTALLING EGR VALVE ASSEMBLY....16316
REMOVE AND INSTALL EGR COOLER ASSEMBLY....16318
METHOD FOR REMOVING EGR COOLER ASSEMBLY....16318
METHOD FOR INSTALLING EGR COOLER ASSEMBLY....16320
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY....16323
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY....16323
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY....16324
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT....16326
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT....16326
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT....16328
REMOVE AND INSTALL ALTERNATOR BELT....16331
METHOD FOR REMOVING ALTERNATOR BELT....16331
METHOD FOR INSTALLING ALTERNATOR BELT....16332
REMOVE AND INSTALL AUTOMATIC TENSIONER....16334
METHOD FOR REMOVING AUTOMATIC TENSIONER....16334
METHOD FOR INSTALLING AUTOMATIC TENSIONER....16334
REMOVE AND INSTALL RADIATOR ASSEMBLY....16335
METHOD FOR REMOVING RADIATOR ASSEMBLY....16335
METHOD FOR INSTALLING RADIATOR ASSEMBLY....16340
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY....16345
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY....16345
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY....16348
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY....16350
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY....16350
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY....16352
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY....16354
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY....16354
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY....16358
REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY....16362
METHOD FOR REMOVING POWER TRAIN OIL COOLER ASSEMBLY....16362
METHOD FOR INSTALLING POWER TRAIN OIL COOLER ASSEMBLY....16367
REMOVE AND INSTALL ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY....16373
METHOD FOR REMOVING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY....16374
METHOD FOR INSTALLING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY....16389
DISCONNECT AND CONNECT ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY....16404
METHOD FOR DISCONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY....16404
METHOD FOR CONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY....16405
REMOVE AND INSTALL ENGINE FRONT OIL SEAL....16407
METHOD FOR REMOVING ENGINE FRONT OIL SEAL....16407
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL....16409
REMOVE AND INSTALL ENGINE REAR OIL SEAL....16412
METHOD FOR REMOVING ENGINE REAR OIL SEAL....16412
METHOD FOR INSTALLING ENGINE REAR OIL SEAL....16413
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY....16420
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY....16420
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY....16426
REMOVE AND INSTALL FUEL TANK ASSEMBLY....16433
METHOD FOR REMOVING FUEL TANK ASSEMBLY....16433
METHOD FOR INSTALLING FUEL TANK ASSEMBLY....16436
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY....16441
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY....16441
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY....16445
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY....16449
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY....16449
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY....16454
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR....16458
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR....16458
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR....16458
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER....16460
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER....16460
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER....16460
REMOVE AND INSTALL KDPF ASSEMBLY....16461
METHOD FOR REMOVING KDPF ASSEMBLY....16463
METHOD FOR INSTALLING KDPF ASSEMBLY....16474
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY....16487
METHOD FOR DISASSEMBLING KDPF ASSEMBLY....16487
METHOD FOR ASSEMBLING KDPF ASSEMBLY....16491
REMOVE AND INSTALL SCR ASSEMBLY....16496
METHOD FOR REMOVING SCR ASSEMBLY....16497
METHOD FOR INSTALLING SCR ASSEMBLY....16506
REMOVE AND INSTALL KDPF, SCR ASSEMBLY....16518
METHOD FOR REMOVING KDPF, SCR ASSEMBLY....16519
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY....16528
REMOVE AND INSTALL KCCV ASSEMBLY....16538
METHOD FOR REMOVING KCCV ASSEMBLY....16538
METHOD FOR INSTALLING KCCV ASSEMBLY....16538
REMOVE AND INSTALL KVGT ASSEMBLY....16540
METHOD FOR REMOVING KVGT ASSEMBLY....16540
METHOD FOR INSTALLING KVGT ASSEMBLY....16546
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE....16552
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE....16553
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE....16559
REMOVE AND INSTALL AdBlue/DEF INJECTOR....16568
METHOD FOR REMOVING AdBlue/DEF INJECTOR....16568
METHOD FOR INSTALLING AdBlue/DEF INJECTOR....16572
REMOVE AND INSTALL AdBlue/DEF PUMP....16576
METHOD FOR REMOVING AdBlue/DEF PUMP....16576
METHOD FOR INSTALLING AdBlue/DEF PUMP....16579
REMOVE AND INSTALL AdBlue/DEF HOSE....16582
METHOD FOR REMOVING AdBlue/DEF HOSE....16583
METHOD FOR INSTALLING AdBlue/DEF HOSE....16592
REMOVE AND INSTALL AIR CLEANER ASSEMBLY....16603
METHOD FOR REMOVING AIR CLEANER ASSEMBLY....16603
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY....16604
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY....16606
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY....16606
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY....16607
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY....16609
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY....16609
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY....16610
POWER TRAIN....16612
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY....16612
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY....16612
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY....16616
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY....16624
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY....16626
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY....16644
DISASSEMBLE AND ASSEMBLE TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY....16671
METHOD FOR DISASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY....16672
METHOD FOR ASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY....16688
REMOVE AND INSTALL FRONT AXLE ASSEMBLY....16708
METHOD FOR REMOVING FRONT AXLE ASSEMBLY....16708
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY....16710
REMOVE AND INSTALL REAR AXLE ASSEMBLY....16712
METHOD FOR REMOVING REAR AXLE ASSEMBLY....16712
METHOD FOR INSTALLING REAR AXLE ASSEMBLY....16719
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY....16727
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY....16728
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY....16733
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY....16741
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY....16742
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY....16751
STEERING SYSTEM....16770
REMOVE AND INSTALL STEERING VALVE ASSEMBLY....16770
METHOD FOR REMOVING STEERING VALVE ASSEMBLY....16770
METHOD FOR INSTALLING STEERING VALVE ASSEMBLY....16772
BRAKE SYSTEM....16775
REMOVE AND INSTALL PARKING BRAKE DISC AND PLATE....16775
METHOD FOR REMOVING PARKING BRAKE DISC AND PLATE....16775
METHOD FOR INSTALLING PARKING BRAKE DISC AND PLATE....16778
UNDERCARRIAGE AND FRAME....16781
REMOVE AND INSTALL CENTER HINGE PIN....16781
METHOD FOR REMOVING CENTER HINGE PIN....16781
METHOD FOR INSTALLING CENTER HINGE PIN....16787
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY....16794
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY....16794
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY....16796
REMOVE AND INSTALL FULL-LENGTH FENDER ASSEMBLY....16800
METHOD FOR REMOVING FULL-LENGTH FENDER ASSEMBLY....16800
METHOD FOR INSTALLING FULL-LENGTH FENDER ASSEMBLY....16801
HYDRAULIC SYSTEM....16802
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY....16802
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY....16802
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY....16806
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY....16810
METHOD FOR REMOVING WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY....16810
METHOD FOR INSTALLING WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY....16811
REMOVE AND INSTALL STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY....16813
METHOD FOR REMOVING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY....16813
METHOD FOR INSTALLING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY....16814
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY....16817
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY....16817
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY....16820
WORK EQUIPMENT....16824
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY....16824
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY....16824
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY....16828
DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLY....16833
METHOD FOR DISASSEMBLING HYDRAULIC CYLINDER ASSEMBLY....16834
METHOD FOR ASSEMBLING HYDRAULIC CYLINDER ASSEMBLY....16837
CAB AND ITS ATTACHMENTS....16843
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY....16843
METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY....16843
METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY....16848
REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS)....16853
METHOD FOR REMOVING OPERATOR'S CAB GLASS (ADHERED GLASS)....16853
METHOD FOR INSTALLING OPERATOR'S CAB GLASS (ADHERED GLASS)....16854
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY....16863
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY....16863
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY....16869
REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY....16874
METHOD FOR REMOVING OPERATOR'S SEAT ASSEMBLY....16874
METHOD FOR INSTALLING OPERATOR'S SEAT ASSEMBLY....16876
REMOVE AND INSTALL SEAT BELT....16878
METHOD FOR REMOVING SEAT BELT....16878
METHOD FOR INSTALLING SEAT BELT....16878
ELECTRICAL SYSTEM....16880
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY....16880
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY....16880
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY....16882
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY....16885
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY....16885
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY....16886
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY....16889
METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY....16889
METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY....16889
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY....16891
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY....16891
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY....16893
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY....16895
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY....16895
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY....16896
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR....16898
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR....16898
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR....16899
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR....16900
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR....16900
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR....16901
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR....16902
METHOD FOR REMOVING KDPF TEMPERATURE SENSOR....16902
METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR....16907
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR....16912
METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR....16912
METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR....16917
REMOVE AND INSTALL SCR TEMPERATURE SENSOR....16921
METHOD FOR REMOVING SCR TEMPERATURE SENSOR....16921
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR....16925
REMOVE AND INSTALL AMMONIA SENSOR....16930
METHOD FOR REMOVING AMMONIA SENSOR....16930
METHOD FOR INSTALLING AMMONIA SENSOR....16934
REMOVE AND INSTALL SCR OUTLET NOx SENSOR....16939
METHOD FOR REMOVING SCR OUTLET NOx SENSOR....16939
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR....16943
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY....16948
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY....16948
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY....16949
60 MAINTENANCE STANDARD....16950
CONTENTS....16951
ABBREVIATION LIST....16953
ENGINE AND COOLING SYSTEM....16959
MAINTENANCE STANDARD OF ENGINE MOUNT....16959
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP....16960
MAINTENANCE STANDARD OF SERVO VALVE OF BRAKE AND COOLING FAN PUMP....16962
MAINTENANCE STANDARD OF COOLING FAN MOTOR....16963
POWER TRAIN....16965
MAINTENANCE STANDARD OF DRIVE SHAFT....16965
MAINTENANCE STANDARD OF TORQUE CONVERTER....16966
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV....16968
MAINTENANCE STANDARD OF TRANSMISSION....16969
MAINTENANCE STANDARD OF F, 1ST CLUTCH....16975
MAINTENANCE STANDARD OF R, 2ND CLUTCH....16977
MAINTENANCE STANDARD OF 3RD, 4TH CLUTCH....16979
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE....16981
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND CLUTCH ECMV....16983
MAINTENANCE STANDARD OF 3RD, 4TH CLUTCH ECMV....16984
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE....16985
MAINTENANCE STANDARD OF FRONT AXLE....16986
MAINTENANCE STANDARD OF REAR AXLE....16987
MAINTENANCE STANDARD OF FRONT CONVENTIONAL DIFFERENTIAL....16988
MAINTENANCE STANDARD OF REAR CONVENTIONAL DIFFERENTIAL....16991
MAINTENANCE STANDARD OF FRONT LIMITED SLIP DIFFERENTIAL....16994
MAINTENANCE STANDARD OF REAR LIMITED SLIP DIFFERENTIAL....16996
MAINTENANCE STANDARD OF FINAL DRIVE....16998
STEERING SYSTEM....17001
MAINTENANCE STANDARD OF STEERING COLUMN....17001
MAINTENANCE STANDARD OF STEERING PUMP....17002
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING PUMP....17005
MAINTENANCE STANDARD OF STEERING VALVE....17006
MAINTENANCE STANDARD OF STEERING CYLINDER....17008
MAINTENANCE STANDARD OF SECONDARY STEERING PUMP....17010
BRAKE SYSTEM....17011
MAINTENANCE STANDARD OF CHARGE VALVE....17011
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR....17013
MAINTENANCE STANDARD OF SLACK ADJUSTER....17014
MAINTENANCE STANDARD OF FRONT BRAKE....17015
MAINTENANCE STANDARD OF REAR BRAKE....17016
MAINTENANCE STANDARD OF PARKING BRAKE....17017
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE....17019
MAINTENANCE STANDARD OF FLOW PRIORITY VALVE....17020
MAINTENANCE STANDARD OF BRAKE COOLING PUMP....17021
MAINTENANCE STANDARD OF BRAKE COOLING STRAINER....17022
UNDERCARRIAGE AND FRAME....17023
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN....17023
HYDRAULIC SYSTEM....17028
MAINTENANCE STANDARD OF HYDRAULIC TANK....17028
MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP....17030
MAINTENANCE STANDARD OF POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP....17032
MAINTENANCE STANDARD OF CONTROL VALVE....17033
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE....17042
WORK EQUIPMENT....17043
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE....17043
MAINTENANCE STANDARD OF BUCKET....17047
MAINTENANCE STANDARD OF LIFT CYLINDER....17048
MAINTENANCE STANDARD OF BUCKET CYLINDER....17049
80 APPENDIX....17050
CONTENTS....17051
ABBREVIATION LIST....17053
AIR CONDITIONER SYSTEM....17059
PRECAUTIONS FOR REFRIGERANT....17059
AIR CONDITIONER COMPONENT....17060
SPECIFICATIONS OF AIR CONDITIONER....17062
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE....17063
OUTLINE OF REFRIGERATION CYCLE....17064
COMPONENT PARTS OF AIR CONDITIONER SYSTEM....17066
AIR CONDITIONER UNIT....17066
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT....17066
FUNCTION OF AIR CONDITIONER UNIT....17067
COMPONENT PARTS OF AIR CONDITIONER UNIT....17068
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT....17068
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT....17068
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT....17069
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT....17069
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT....17069
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT....17069
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT....17069
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT....17069
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT....17070
FUNCTION OF DUAL PRESSURE SWITCH....17070
AIR CONDITIONER CONTROLLER....17071
STRUCTURE OF AIR CONDITIONER CONTROLLER....17071
COMPRESSOR....17072
STRUCTURE OF COMPRESSOR....17072
SPECIFICATIONS OF COMPRESSOR....17072
FUNCTION OF COMPRESSOR....17072
CONDENSER....17073
STRUCTURE OF CONDENSER....17073
SPECIFICATIONS OF CONDENSER....17073
FUNCTION OF CONDENSER....17073
RECEIVER DRIER....17074
STRUCTURE OF RECEIVER DRIER....17074
SPECIFICATIONS OF RECEIVER DRIER....17074
FUNCTION OF RECEIVER DRIER....17074
SENSORS FOR AIR CONDITIONER SYSTEM....17075
FUNCTION OF SUNLIGHT SENSOR....17075
FUNCTION OF AMBIENT TEMPERATURE SENSOR....17075
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER....17076
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER....17078
AIR CONDITIONER SYSTEM DIAGRAM....17081
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER....17082
FUNCTION OF AIR CONDITIONER CONTROLLER....17083
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS....17084
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION....17090
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR....17091
CHECK TEMPERATURE CONTROL FUNCTION....17092
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION....17092
TEST VENT (MODE) CHANGEOVER....17094
METHOD FOR TESTING VENT (MODE) CHANGEOVER....17094
TESTING FRESH/RECIRC AIR CHANGEOVER....17096
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER....17096
TEST EVAPORATOR TEMPERATURE SENSOR....17098
TEST RELAYS....17100
METHOD FOR TESTING RELAYS....17100
AIR CONDITIONER TROUBLESHOOTING CHART 1....17102
AIR CONDITIONER TROUBLESHOOTING CHART 2....17103
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE....17106
FAILURE CODE [879AKA]....17108
FAILURE CODE [879AKB]....17110
FAILURE CODE [879BKA]....17112
FAILURE CODE [879BKB]....17114
FAILURE CODE [879CKA]....17116
FAILURE CODE [879CKB]....17118
FAILURE CODE [879DKZ]....17120
FAILURE CODE [879EMC]....17122
FAILURE CODE [879FMC]....17125
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)....17128
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)....17131
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)....17134
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER....17138
TROUBLESHOOTING USING GAUGE PRESSURE....17140
CONNECTION OF SERVICE TOOL....17143
METHOD FOR CONNECTING SERVICE TOOL....17144
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS....17145
HANDLE COMPRESSOR OIL....17147
90 CIRCUIT DIAGRAMS....17150
CONTENTS....17151
ABBREVIATION LIST....17152
HYDRAULIC CIRCUIT DIAGRAM....17158
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM....17158
HYDRAULIC CIRCUIT DIAGRAM (FOR STEERING WHEEL SPEC)....17162
HYDRAULIC CIRCUIT DIAGRAM (FOR JOYSTICK STEERING SPEC)....17163
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM....17164
HYDRAULIC OIL PRESSURE OF BRAKE COOLING SYSTEM....17166
HYDRAULIC AUTO-GREASING DIAGRAM....17168
ELECTRICAL CIRCUIT DIAGRAM....17169
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM....17169
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/9)....17173
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/9)....17174
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/9)....17175
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/9)....17176
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/9)....17177
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/9)....17178
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/9)....17179
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/9)....17180
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/9)....17181
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (1/8)....17182
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (2/8)....17183
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (3/8)....17184
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (4/8)....17185
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (5/8)....17186
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (6/8)....17187
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (7/8)....17188
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (8/8)....17189
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (1/9)....17190
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (2/9)....17191
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (3/9)....17192
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (4/9)....17193
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (5/9)....17194
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (6/9)....17195
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (7/9)....17196
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (8/9)....17197
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (9/9)....17198
INDEX....17199
SMEW4700K0 - avance Loader Custom avance WA470-3 Shop Manual (Serial Number WA470-3 20001 & up)....17221
COVER....17221
CONTENTS....17223
01GENERAL....17235
GENERAL ASSEMBLY DRAWING....17236
SPECIFICATIONS....17237
WEIGHT TABLE....17241
LIST OF LUBRICANT AND WATER....17242
10 STRUCTURE AND FUNCTION....17244
POWER TRAIN....17246
POWER TRAIN SYSTEM....17247
TORQUE CONVERTER，TRANSMISSION PIPING....17249
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM....17251
TRANSMISSINO HYDRAULIC CIRCUIT DIAGRAM....17252
TORQUE CONVERTER....17253
TORQUE CONVERTER OIL FILTER....17256
TRANSMISSION....17257
TRANSMISSION CONTROL VALVE....17268
TRANSMISSION SOLENOID VALVE....17289
PILOT OIL FILTER....17290
DRIVE SHAFT....17291
AXLE ....17292
DIFFERENTIAL....17294
FINAL DRIVE....17298
AXLE MOUNT CENTER HINGE PIN....17299
STEERING PIPING....17300
STEERING COLUMN....17301
STEERING VALVE....17302
ORBIT-ROLL VALVE....17316
STOP VALVE....17320
BRAKE PIPING....17321
BRAKE CIRCUIT DIAGRAM....17323
BRAKE VALVE....17324
CHARGE VALVE....17328
ACCUMULATOR（FOR BRAKE）....17332
SLACK ADJUSTER....17333
BRAKE....17336
PARKING BRAKE CONTROL....17338
PARKING BRAKE....17339
PARKING BRAKE SOLENOID VALVE....17340
PARKING BRAKE VALVE....17341
HYDRAULIC PIPING....17342
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM....17343
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM....17345
WORK EQUIPMENT LEVER LINKAGE....17347
HYDRAULIC TANK....17348
PPC VALVE....17350
PPC RELIEF VALVE....17355
ACCUMULATOR（FOR PPC VALVE）....17356
MAIN CONTROL VALVE....17357
WORK EQUIPMENT LINKAGE....17369
BUCKET....17371
BUCKET PISITIONER AND BOOM KICK-OUT....17372
CAB....17378
AIR CONDITIONER....17379
SENSORS....17380
ENGINE STARTING CIRCUIT....17384
ENGINE STOP CIRCUIT....17385
PREHEATING CIRCUIT....17386
ELECTRIC TRANSMISSION CONTROL....17387
KICK-DOWN HOLD SWITCH....17390
TRANSMISSION CUT-OFF SWITCH....17400
ELECTRIC CIRCUIT DIAGRAM....17412
20 TESTING AND ADJUSTING....17415
STANDARD VALUE TABLE FOR ENGINE....17416
STANDARD VALUE TABLE FOR CHASSIS....17417
STANDARD VALUE TABLE FOR ELECTRICAL PARTS....17420
TOOLS FOR TESTING，ADJUSTING AND TROUBLESHOOTING....17424
MEASURING ENGINE SPEED....17425
MEASURING INTAKE AIR PRESSURE（BOOST PRESSURE）....17426
ADJUSTING VALVE CLEARANCE....17427
MEASURING EXHAUST COLOR....17428
MEASURING EXHAUST GAS TEMPERATURE....17429
MEASUREING BLOW-BY PRESSURE....17430
MEASURING COMPRESSION PRESSURE....17431
MEASURING ENGINE OIL PRESSURE....17432
TESTING AND ADJUSTING FUEL INJECTION TIMING....17433
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE....17435
TESTING AND ADJUSTING FAN BELT TENSION....17437
MEASURING ACCELERATOR PEDAL....17438
MEASURING OPERATING FORCE， TRAVEL OF SPEED LEVER....17440
MEASURING STALL SPEED....17441
MEASURING TORQUE CONVERTER，TRANSMISSION，PARKING BRAKE OIL PRESSURE....17443
METHOD OF OPERATING EMERGENCY MANUAL SPOOL....17445
MEASURING CLEARANCE BETWEEN TIRE AND WHEEL....17447
TESTING AND ADJUSTING STEERING WHEEL....17448
TESTING AND ADJUSTING STEERING CONTROL....17451
MEASURING STEERING OIL PRESSURE....17452
MEASURING OPERATING FORCE，TRAVEL OF BRAKE PEDAL....17454
TESTING BRAKE OIL PRESSURE....17455
MEASURING BRAKE PERFORANCE....17456
MEASURING BRAKE DISC WEAR....17457
BLEEDING AIR FROM BRAKE SYSTEM....17458
MEASURING PARKING BRAKE PERFORMANCE....17459
MANUAL RELEASE METHOD FOR PARKING BRAKE....17460
TESTING WEAR OF PARKING BRAKE DISC....17461
MEASURING WORK EQUIPMENT CONTROL LEVER....17462
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE....17464
MEASURING WORK EQUIPMENT....17468
TESTING AND ADJUSTING BUCKET POSITIONER....17470
TESTING AND ADJUSTING BOOM KICK-OUT....17471
TROUBLESHOOTING....17473
POINTS TO REMEMBER WHEN TROUBLESHOOTING....17474
SEQUENCE OF EVENTS IN TROUBLESHOOTING....17475
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE....17476
HANDLING CONNECTORS....17483
CHECKS BEFORE TROUBLESHOOTING....17484
CONNECTOR TYPES AND MOUNTING LOCATIONS....17485
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....17491
TROUBLESHOOTING OF ENGINE SYSTEM（S MODE）....17498
S-1 STARTING PERFORMANCE IS POOR....17499
S-2 ENGINE DOES NOT START....17500
(1) ENGINE DOES NOT TURN....17500
(2) ENGINE TURNS BUT TO EXHAUST GAS COMES OUT ....17501
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START....17502
S-3 ENGINE DOES NOT PICK UP SMOOTHLY....17503
S-4 ENGINE STOPS DURING OPERATIONS....17504
S-5 ENGINE DOES NOT ROTATE SMOOTHLY....17505
S-6 ENGINE LACKS OUTPUT....17506
S-7 EXHAUST GAS IS BLACK....17507
S-8 OIL CONSUMPTION IS EXCESSIVE ....17508
S-9 OIL BECOMES CONTAMINATED QUICKLY....17509
S-10 FUEL CONSUMPTION IS EXCESSIVE....17510
S-11 OIL IS IN COOLING WATER， OR WATER SPURTS BACK，OR WATER LEVEL GOES DOWN....17511
S-12 OIL PRESSURE PAMP LIGHTS UP....17512
S-13 OIL LEVEL RISES....17513
S-14 WATER TEMPERATURE BECOMES TOO HIGH....17514
S-15 ABNORMAL NOISE MADE....17515
S-16 VIBRATION IS EXCESSIVE....17516
TROUBLESHOOTING OF HYDRAULIC AND MACHANICAL SYSTEM（T MODE）....17517
POWER DRAIN....17518
T-1 MACHINE DOES NOT START....17518
T-2 TRAVEL SPEED IS SLOW，THRUSTING POWER IS WEAK，LACKS POWER ON SLOPES....17520
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR....17522
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR....17523
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH....17524
STEERING SYSTEM....17525
T-6 STEERING WHEEL DOES NOT TURN....17525
T-7 STEERING WHEEL IS HEAVY....17526
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK....17527
T-9 MACHINE STEERS TO ONE SIDE WHEN TRAVELING....17527
T-10 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT....17527
BRAKE SYSTEM....17528
T-11 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR....17528
T-12 BRAKES ARE NOT RELEASED OR BRAKES DRAG....17529
T-13 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS....17530
WORK EQUIPMENT....17531
T-14 BOOM DOES NOT RISE....17531
T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER....17532
T-16 WHEN BOOM IS RAISED，IT MOVES SLOWLY AT A CERTAIN HEIGHT....17533
T-17 BUCKET CAN NOT BE PUSHED WITH BOOM CYLINDER....17533
T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM....17533
T-19 BOOM SHAKES DURING OPERATION....17533
T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE....17534
T-21 BUCKET DOES NOT TILT BACK....17535
T-22 BUCKET MOVEMENT IS SLOW OR TILT BACK LACKS POWER....17536
T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATIOIN....17537
T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER....17537
T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET....17537
T-26 BUCKET SHAKES DURING LOADING OPERATION....17538
T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLE TO TILT....17538
T-28 BOOM，BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY....17539
TROUBLESHOOTING OF ELECTRICAL SYSTEM（E MODE）....17540
E-1 ENGINE DOES NOT START....17541
(a) STARTING MOTOR DOES NOT TURN....17541
(b) STARTING MOTOR TURNS....17545
E-2 ENGINE DOES NOT STOP....17547
E-3 ENGINE STOPS WHEN MACHINE IS TRAVLING....17547
E-4 PARKING BRAKE DOES NOT WORK....17548
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING....17549
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON....17551
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED....17551
E-8 TRANSMISSION DOES NOT WORK NORMALLY....17552
(a) PROBLEM IN COMMON CIRCUIT FOR TRANSMISSION ....17554
(b) PROBLEM IN H-L CIRCUIT....17554
(c) PROBLEM IN SPEED CIRCUIT....17555
(d) PROBLEM IN 4TH CIRCUIT ....17555
(e) CONTACT IN H-L CIRCUIT....17556
(f) CONTACT IN SPEED CIRCUIT....17558
(g) CONTACT IN 4TH CIRCUIT....17560
(h) PROBLEM IN FORWARD CIRCUIT....17561
(i) PROBLEM IN REVERSE CIRCUIT....17563
(j) PROBLEM IN COMMON CIRCUIT FO FORWARD AND REVERSE....17565
(k) CONTACT IN FORWARD CIRCUIT....17567
(l) CONTACT IN REVERSE CIRCUIT....17569
(m) PROBLEM IN REVERSE CIRCUIT....17571
E-9 KICK-DOWN SWITCH DOES NOT WORK....17572
E-10 KICK-DOWN WORKS ONLY WHEN KICK-DOWN IS ON....17574
E-11 KICK-DOWN OPERATION CANNOT BE CANCELED....17574
(a) NOT CANCELED EVEN WHEN DIRECTIONAL LEVER IS MOVED FROM F TO N OR R....17574
(b) NOT CANCELED EVEN WHEN SPEED LEVER IS MOVED FROM 2ND TO OTHER POSITON....17575
E-12 KICK-DOWN SWITCH IS ACTUATED BY MISTAKE WHEN TRAVELING IN 2ND....17577
30 DISASSEMBLY AND ASSEMBLY....17578
METHOD OF USING MANUAL....17580
PRECAUTIONS WHEN CARRYING OUT OPERATION....17581
COMMON TOOL LIST....17583
STARTING MOTOR....17584
REMOVAL ....17584
INSTALLATION....17584
ALTERNATOR....17585
REMOVAL ....17585
INSTALLATION....17585
ENGINE OIL COOLER....17586
REMOVAL....17586
INSTALLATION....17586
FUEL INJECTION PUMP....17587
REMOVAL....17587
INSTALLATION....17588
WATER PUMP....17589
REMOVAL....17589
INSTALLATION....17589
TURBOCHARGER ....17590
REMOVAL....17590
INSTALLATION....17590
NOZZLE HOLDER....17591
REMOVAL....17591
INSTALLATION....17591
THERMOSTAT....17592
REMOVAL....17592
INSTALLATION....17592
CYLINDER HEAD....17593
REMOVAL....17593
INSTALLATION....17597
RADIATOR....17599
REMOVAL....17599
INSTALLATION....17601
ENGINE....17602
REMOVAL....17602
INSTALLATION....17607
TORQUE CONVERTER,TRANSMISSION....17608
REMOVAL....17608
INSTALLATION....17615
TORQUE CONVERTER....17619
ASSEMBLY....17619
DISASSEMBLY....17620
TRANSMISSION....17623
DISASSEMBLY....17623
ASSEMBLY....17628
TRANSMISSION CLUTCH PACK....17634
DISASSEMBLY....17634
ASSEMBLY....17643
PARKING BRAKE....17656
DISASSEMBLY....17656
ASSEMBLY....17658
TRANSMISSION CONTROL VALVE....17663
INSTALLATION....17663
DISASSEMBLY....17664
REMOVAL....17665
ASSEMBLY....17670
TRANSMISSION ACCUMULATOR VALVE....17676
DISASSEMBLY....17676
ASSEMBLY....17677
DRIVE SHAFT....17680
DISASSEMBLY....17678
ASSEMBLY....17680
FRONT AXLE....17682
REMOVAL....17682
INSTALLATION....17684
REAR AXLE....17685
REMOVAL....17685
INSTALLATION....17688
FRONT DIFFERENTIAL ....17690
REMOVAL....17690
INSTALLATION....17693
REAR DIFFERENTIAL....17695
REMOVAL....17695
INSTALLATION....17698
DIFFERENTIAL....17700
DISASSEMBLY....17700
ASSEMBLY....17703
FINAL DRIVE....17711
DISASSEMBLY....17711
ASSEMBLY....17714
CENTER HINGE PIN....17718
REMOVAL....17718
INSTALLATION....17727
STEERING VALVE(ORBIT ROLL)....17733
REMOVAL....17733
INSTALLATION....17734
DISASSEMBLY....17735
ASSEMBLY....17738
STEERING VALVE....17743
REMOVAL....17743
INSTALLATIONG....17744
STEERING DEMAND VALVE....17745
DISASSEMBLY....17745
ASSEMBLY....17749
STEERING SWITCH PUMP....17753
REMOVAL....17753
INSTALLATION....17756
STEERING CYLINDER....17757
REMOVAL....17757
INSTALLATION....17758
BRAKE VALVE....17759
REMOVAL....17759
INSTALLATION....17760
DISASSEMBLY....17761
ASSEMBLY....17762
SLACK ADJUSTER....17763
REMOVAL....17763
INSTALLATION....17764
DISASSEMBLY....17765
ASSEMBLY....17766
BRAKE....17767
DISASSEMBLY....17767
ASSEMBLY....17773
PARKING BRAKE DISC....17781
REMOVAL....17781
INSTALLATON....17783
HYDRAULIC TANK....17784
REMOVAL....17784
INSTALLATION....17786
WORK EQUIPMENT,PPC PUMP....17787
REMOVAL....17787
INSTALLATION....17790
PPC VALVE....17791
REMOVAL....17791
INSTALLATION....17792
DISASSEMBLY....17793
ASSEMBLY....17794
MAIN CONTROL VALVE....17795
REMOVAL....17795
INSTALLATION....17797
DISASSEMBLY....17798
ASSEMBLY....17800
BUCKET CYLINDER....17802
REMOVAL....17802
INSTALLATION....17803
BOOM CYLINDER....17804
REMOVAL....17804
INSTALLATION....17805
HYDRAULCI CYLINDER....17806
DISASSEMBLY....17806
ASSEMBLY....17809
WORK EQUIPMENT....17812
REMOVAL....17812
INSTALLATION....17815
COUNTERWEIGHT....17817
REMOVAL....17817
INSTALLATION....17817
FUEL TANK....17818
REMOVAL....17818
INSTALLATION....17819
CAB,FLOOR FRAME....17820
REMOVAL....17820
INSTALLATION....17823
GAUGE PANEL....17826
REMOVAL....17826
INSTALLATION....17826
AIR CONDITIONER UNT....17827
REMOVAL....17827
INSTALLATION....17831
CONDERSER ....17832
REMOVAL....17832
INSTALLATION....17833
RECEIVER....17835
REMOVAL....17835
INSTALLATION....17835
AIR CONDITIONER CONDESER COMPRESSOR....17837
REMOVAL....17837
INSTALLATION....17837
40 MAINTENANCE STANDARD....17839
ENGINE MOUNT TRANSMISSION MOUNT....17840
TORQUE CONVERTER....17841
TRANSMISSION....17842
TRANSMISSION CONTROL VALVE....17849
DRIVE SHAFT....17853
DIFFERENTIAL....17854
FINAL DRIVE....17856
AXLE MOUNT....17857
STEERING COLUMN....17858
STEERING VALVE....17859
STEERING CYLINDER MOUNT....17860
SLACK ADJUSTER....17861
BRAKE VALVE....17862
BRAKE....17864
PARKING BRAKE....17866
TORQUE CONVERTER,TRANSMISSION PUMP....17867
STEERING,SWITCH PUMP....17868
HYDRAULIC,PPC PUMP....17869
PPC VALVE....17870
CUT-OFF VALVE....17871
MAIN CONTROL VALVE....17872
BOOM CYLINDER....17876
BUCKET CYLINDER....17877
CENTER HINGE PIN....17878
WORK EQUIPMENT LINAGE....17880
BUCKET....17882
BUCKET POSITIONER AND BOOM KICK-OUT....17883
PROPOSAL....17884
SMEW4700M0 - Wheel Loader MAX avance WA470-3 Shop Manual (Serial Number WA470H-20051 & up)....17885
COVER....17885
CONTENTS....17886
SAFETY....17887
FOREWORD....17889
01 GENERAL....17898
GENERAL ASSEMBLY DRAWING ....17899
SPECIFICATIONS....17900
WEIGHT TABLE....17903
LIST OF LUBRICANT AND WATER....17905
10 STRUCTURE AND FUNCTION....17907
POWER TRAIN....17909
POWER TRAIN SYSTEM....17910
TORQUE CONVERTER,TRANSMISSION PIPING....17912
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM....17914
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM....17915
TORQUE CONVERTER....17916
TORQUE CONVERTER OIL FILTER....17919
TRANSMISSION ....17920
TRANSMISSION CONTROL VALVE....17931
TRANSMISSION SOLENOID VALVE....17952
PILOT OIL FILTER....17953
DRIVER SHAFT....17954
AXLE....17955
DIFFERENTIAL....17957
FINAL DRIVE....17961
AXLE MOUNT,CENTER HINGE PIN....17962
STEERING PIPING....17963
STEERING COLUMN....17964
STEERING VALVE....17965
ORBIT-ROLL VALVE....17979
STOP VALVE....17983
BRAKE PIPING....17984
BRAKE CIRCUIT DIAGRAM....17986
BRAKE VALVE....17987
CHARGE VALVE....17991
ACCUMULATOR(FOR BRAKE)....17995
SLACK ADJUSTER....17996
BRAKE....17999
PARKING BRAKE CONTROL....18001
PARKING BRAKE....18002
PARKING BRAKE SOLENOID VALVE....18003
PARKING BRAKE VALVE....18004
HYDRAULIC PIPING....18005
WORK EQUIPMENT HYDRAULIC DIAGRAM....18006
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM....18008
WORK EQUIPMENT LEVER LINKAGE....18010
HYDRAULIC TANK....18011
PPC VALVE....18013
PPC RELIEF VALVE....18018
ACCUMULATOR(FOR PPC VALVE)....18019
MAIN CONTROL VALVE....18020
WORK EQUIPMENT LINKAGE....18032
BUCKET....18034
BUCKET POSITIONER AND BOOM KICK-OUT....18035
CAB....18041
AIR CONDITIONER....18042
SENSORS....18043
ENGINE STARTING CIRCUIT....18047
ENGINE STOP CIRCUIT....18048
PREHEATING CIRCUIT....18049
ELECTRIC TRANSMISSION CONTROL....18050
KICK-DOWN,HOLD SWITCH....18053
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM....18054
TRANSMISSION CUT-OFF SWITCH....18058
未标题....18059
20 TESTING AND ADJUSTING....18061
STANDARD VALUE TABLE FOR ENGINE....18062
STANDARD VALUE TABLE FOR CHASSIS....18063
STANDARD VALUE TABLE FOR ELECTRICAL PARTS....18066
TOOLS FOR TESTING,ADJUSTING AND TROUBLESHOOTING....18069
MEASURING ENGINE SPEED....18070
MEASURING INTAKE AIR PRESSURE(BOOST PRESSURE)....18071
ADJUSTING VALVE CLEARANCE....18072
MEASURING EXHAUST COLOR....18073
MEASURING EXHAUST GAS TEMPERATURE....18074
MEASURING BLOW-BY PRESSURE....18075
MEASURING COMPRESSION PRESSURE....18076
MEASURING ENGINE OIL PRESSURE....18077
TESTING AND ADJUSTING FUEL INJECTION TIMING....18078
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE....18080
TESTING AND ADJUSTING FAN BELT TENSION....18082
MEASURING ACCELERATOR PEDAL....18083
MEASURING OPERATING FORCE,TRAVEL OF SPEED LEVER....18085
MEASURING STALL SPEED....18086
MEASURING TORQUE CONVERTER,TRANSMISSION,PARKING BRAKE OIL PRESSURE....18088
METHOD OF OPERATING EMERGENCY MANUAL SPOOL....18090
MEASURING CLEARANCE BETWEEN TIRE AND WHEEL....18092
TESTING AND ADJUSTING STEERING WHEEL....18093
TESTING AND ADJUSTING STEERING CONTROL....18096
MEASURING STEERING OIL PRESSURE....18097
MEASURING OPERATING FORCE,TRAVEL OF BRAKE PEDAL....18099
TESTING BRAKE OIL PRESSURE....18100
MEASURING BRAKE PERFORMANCE....18101
MEASURING BRAKE DISC WEAR....18102
BLEEDING AIR FROM BRAKE SYSTEM....18103
MEASURING PARKING BRAKE PERFORMANCE....18104
MANUAL RELEASE METHOD FOR PARKING BRAKE....18105
TESTING WEAR OF PARKING BRAKE DISC....18106
MEASURING WORK EQUIPMENT CONTROL LEVER....18107
MEASURING WORK EQUIPMNT HYDRAULIC PRESSURE....18109
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE....18109
MEASURING WORK EQUIPMENT....18113
TESTING AND ADJUSTING BUCKET POSITIONER....18115
TESTING AND ADJUSTING BOOM KICK-OUT....18116
TROUBLESHOOTING....18119
POINTS TO REMEMBER WHEN TROUBLESHOOTING....18120
SEQUENCE OF EVENTS IN TROUBLESHOOTING....18121
PRECAUTIONS WHEN CARRYING OUT MAINTENACE....18122
HANDLING CONNECTORS....18129
CHECKS BEFORE TROUBLESHOOTING....18130
CONNECTOR TYPES AND MOUNTING LOCATIONS....18131
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....18136
TROUBLESHOOTING OF ENGINE SYSTEM(S MODE)....18143
S-1 STARTING PERFORMANCE IS POOR....18144
S-2 ENGINE DOES NOT START....18145
S-3 ENGINE DOES NOT PICK UP SMOOTHLY....18148
S-4 ENGINE STOPS DURING OPERATIONS....18149
S-5 ENGINE DOSE NOT ROTATE SMOOTHLY....18150
S-6 ENGINE LACKS OUTPUT....18151
S-7 EXHAUST GAS IS BLACK....18152
S-8 OIL CONSUMPTION IS EXCESSIVE....18153
S-9 OIL BECOMES CONTAMINATED QUICKLY....18154
S-10 FUEL CONSUMPTION IS EXCESSIVE....18155
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN....18156
S-12 OIL PRESSURE LAMP LIGHTS UP....18157
S-13 OIL LEVEL RISES....18158
S-14 WATER TEMPERATURE BECOMES TOO HIGHT....18159
S-15 ABNORMAL NOISE IS MADE....18160
S-16 VIBRATION IS EXCESSIVE....18161
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM(CHASSIS RELATED)(T MODE)....18162
POWER TRAIN....18163
STEERING SYSTEM....18170
BRAKE SYSTEM....18173
WORK EQUIPMENT....18176
TROUBLESHOOTING OF ELECTRICAL SYSTEM(E MODE)....18185
E-1 ENGINE DOES NOT START....18186
E-2 ENGINE DOES NOT STOP....18192
E-3 ENGINE STOP WHEN MACHINE IS TRAVELING....18192
E-4 PARKING BRAKE DOES NOT WORK....18193
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING....18194
E-6 PARKING BRAKE IS RELESED WHEN STARTING AWITCH IS TURNED ON....18196
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED....18196
E-8 TRANSMISSION DOES NOT WORK NORMALLY....18197
E-9 KICK-DOWN SWITCH DOES NOT WORK....18217
E-10 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS ON....18219
E-11 KICK-DOWN OPERATION CANNOT BE CONCELED....18219
E-12 KICK-DOWN SWITCH IS ACTUATED BY MISTAKE WHEN TRAVELING IN 2ND....18222
30 DISASSEMBLY AND ASSEMBLY....18223
METHOD OF USING MANUAL....18225
PRECATIONS WHEN CARRYING OUT OPERATION....18226
COMMON TOOL LIST....18228
STARTING MOTOR....18229
ALTERNATOR....18230
ENGINE OIL COOLER....18231
FUEL INJECTION PUMP....18232
WATER PUMP....18234
TURBOCHARGER....18235
NOZZLE HOLDER....18236
THERMOSTAT....18237
CYLINDER HEAD....18238
RADIATOR....18244
ENGINE....18247
TORQUE CONVERTER,TRANSMISSION ASSEMBLY....18253
TORQUE CONVERTER....18262
TRANSMISSION....18267
TRANSMISSION CLUTCH PARK....18278
PARKING BRAKE....18299
TRANSMISSION CONTROL VALE....18304
TRANSMISSION ACCUMULATOR VALVE....18318
DRIVE SHAFT....18320
FRONT AXLE....18324
REAR AXLE....18327
FRONT DIFFERENTIAL....18332
REAR DIFFERNTIAL....18337
DIFFERENTIAL....18342
FINAL DRIVE....18353
CENTER HINGE PIN....18360
STEERING VALVE....18375
STEERING DEMAND VALVE....18387
STEERING,SWITCH PUMP....18395
STEERING CYLINDER....18399
BRAKE VALVE....18401
RIGHT BRAKE VALVE....18403
SLACK ADJUSTER....18405
BRAKE....18409
PARKING BRAKE DISC....18423
HYDRAULIC TANK....18426
WORK EQUIPMENT,PPC PUMP....18429
PPC VALVE....18435
MAIN CONTROL VALVE....18437
BUCKET CYLINDER....18444
BOOM CYLINDER....18446
HYDRAULIC CYLINDER....18451
WORK EQUIPMENT....18454
COUNTERWEIGHT....18459
FUEL TANK....18460
CAB FLOOR FRAME....18462
CAB,FLOOR FRAME ASSEMBLY....18465
CAB....18466
GUAGE PANEL....18468
AIR CONDITIONER UNIT....18469
AIR CONDITIONER CONDENSER....18474
RECEIVER....18477
AIR CONDITIONER CONDESER COMPRESSOR....18479
40 MAINTENANCE STANDARD....18480
ENGINE MOUNT,TRANSMISSION MOUNT....18481
TORQUE CONVERTER....18482
TRANSMISSION....18483
TRANSMISSION CONTROL VALVE....18490
DRIVE SHAFT....18494
DIFFERENTIAL....18495
FINAL DRIVE....18497
AXLE MOUNT....18498
STEERING COLUMN....18499
STEERING VALVE....18500
STEERING CLINDER MOUNT....18501
SLACK ADJUSTER....18502
BRAKE VALVE....18503
BRAKE....18505
PARKING BRAKE....18507
TORQUE CONVERTER,TRANSMISSION PUMP....18508
STEERING,SWITCH PUMP....18509
HYDRAULIC,PPC PUMP....18510
PPC VALVE....18511
CUT-OFF VALVE....18512
MAIN CONTROL VALVE....18513
BOOM CYLINDER....18517
BUCKET CYLINDER....18518
CENTER HINGE PIN....18519
WORK EQUIPMENT LINKAGE....18521
BUCKET....18523
BUCKET POSITIONER AND BOOM KICK-OUT....18524
90 ELECTRIC CIRCUIT DIAGRAM....18525
TEN00091-00 - Wheel Loader GALEO WA470-5 Operation & Maintenance Manual....18530
COVER....18530
FOREWORD....18531
FOREWORD....18532
SAFETY INFORMATION....18535
INTRODUCTION....18537
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....18537
NECESSARY INFORMATION....18538
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....18538
ENGINE SERIAL NO. PLATE....18538
POSITION OF SERVICE METER....18539
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....18539
CONTENTS....18540
SAFETY....18543
SAFETY....18544
SAFETY LABELS....18547
LOCATION OF SAFETY LABELS....18547
SAFETY LABELS....18548
GENERAL PRECAUTIONS....18553
SAFETY RULES....18553
IF ABNORMALITIES ARE FOUND....18553
CLOTHING AND PERSONAL PROTECTIVE ITEMS....18553
FIRE EXTINGUISHER AND FIRST AID KIT....18553
SAFETY FEATURES....18553
KEEP MACHINE CLEAN....18554
INSIDE OPERATOR'S COMPARTMENT....18554
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT....18554
HANDRAILS AND STEPS....18555
MOUNTING AND DISMOUNTING....18556
NO PEOPLE ON ATTACHMENTS....18556
DO NOT GET CAUGHT IN ARTICULATED PORTION....18556
PREVENTION OF BURNS....18556
FIRE PREVENTION....18557
ACTION IF FIRE OCCURS....18558
WINDOW WASHER LIQUID....18558
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)....18558
PRECAUTIONS FOR ATTACHMENTS, OPTIONS....18558
UNAUTHORIZED MODIFICATION....18558
SAFETY AT WORKSITE....18559
WORKING ON LOOSE GROUND....18559
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES....18559
ENSURE GOOD VISIBILITY....18560
VENTILATION FOR ENCLOSED AREAS....18560
CHECKING SIGNALMAN'S SIGNALS AND SIGNS....18560
EMERGENCY EXIT FROM OPERATOR'S CAB....18560
BE CAREFUL ABOUT ASBESTOS DUST....18561
PRECAUTIONS FOR OPERATION....18562
STARTING ENGINE....18562
CHECKS BEFORE STARTING ENGINE....18562
PRECAUTIONS WHEN STARTING....18562
PRECAUTIONS IN COLD AREAS....18563
OPERATION....18564
CHECKS BEFORE OPERATION....18564
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE....18564
PRECAUTIONS WHEN TRAVELING....18565
TRAVELING ON SLOPES....18566
PROHIBITED OPERATIONS....18567
PRECAUTIONS WHEN OPERATING....18567
METHODS OF USING BRAKE....18568
OPERATE CAREFULLY ON SNOW....18568
PARKING MACHINE....18569
TRANSPORTATION....18570
LOADING AND UNLOADING....18570
SHIPPING....18570
BATTERY....18571
BATTERY HAZARD PREVENTION....18571
STARTING WITH BOOSTER CABLES....18572
TOWING....18573
WHEN TOWING....18573
PRECAUTIONS FOR MAINTENANCE....18574
WARNING TAG....18574
KEEP WORK PLACE CLEAN AND TIDY....18574
APPOINT LEADER WHEN WORKING WITH OTHERS....18574
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE....18574
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....18576
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.SWITCH OFF....18576
PROPER TOOLS....18577
ACCUMULATOR....18577
PERSONNEL....18577
ATTACHMENTS....18577
WORK UNDER THE MACHINE....18578
NOISE....18578
PRECAUTIONS WHEN USING HAMMER....18578
REPAIR WELDING....18578
REMOVING BATTERY TERMINAL....18578
PRECAUTIONS WITH HIGH-PRESSURE OIL....18579
PRECAUTIONS FOR HIGH-PRESSURE FUEL....18579
HANDLING HIGH-PRESSURE HOSES....18579
PRECAUTIONS FOR HIGH VOLTAGE....18579
WASTE MATERIALS....18580
MAINTENANCE OF AIR CONDITIONER....18580
COMPRESSED AIR....18580
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....18580
PRECAUTIONS WITH TIRES....18581
HANDLING TIRES....18581
PRECAUTIONS WHEN STORING TIRES....18581
OPERATION....18582
GENERAL VIEW....18583
GENERAL VIEW OF MACHINE....18583
GENERAL VIEW OF CONTROLS AND GAUGES....18584
EXPLANATION OF COMPONENTS....18587
MACHINE MONITOR....18587
SWITCHES....18617
CONTROL LEVERS, PEDALS....18632
STEERING TILT LOCK LEVER....18637
CAP WITH LOCK....18638
FRAME LOCK BAR....18640
TOWING PIN....18640
GREASE PUMP....18641
CAB DOOR OPEN LOCK....18641
CAB WINDOW OPEN LOCK CANCEL KNOB....18641
FUSE....18642
SLOW BLOW FUSE....18643
POWER OUTLET....18644
AM/FM RADIO....18645
AM/FM RADIO-CASSETTE STEREO....18651
AIR CONDITIONER....18659
HANDLING AUTO AIR CONDITIONER....18664
HANDLING CAB WIPER....18671
OPERATION....18672
CHECK BEFORE STARTING ENGINE, ADJUST....18672
STARTING ENGINE....18688
OPERATIONS AND CHECKS AFTER STARTING ENGINE....18693
STOPPING ENGINE....18695
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE....18696
TURNING....18707
OPERATION OF WORK EQUIPMENT....18709
WORK POSSIBLE USING WHEEL LOADER....18711
PRECAUTIONS FOR OPERATION....18718
ADJUSTING WORK EQUIPMENT POSTURE....18720
PARKING MACHINE....18722
CHECKS AFTER COMPLETION OF OPERATION....18724
LOCKING....18724
HANDLING THE TIRES....18725
TRANSPORTATION....18727
TRANSPORTATION PROCEDURE....18727
LOADING, UNLOADING WORK WITH TRAILERS....18727
LIFTING MACHINE....18731
COLD WEATHER OPERATION....18733
PRECAUTIONS FOR LOW TEMPERATURE....18733
PRECAUTIONS AFTER COMPLETION OF WORK....18734
AFTER COLD WEATHER....18734
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER....18735
LONG-TERM STORAGE....18736
BEFORE STORAGE....18736
DURING STORAGE....18736
AFTER STORAGE....18736
TROUBLESHOOTING....18737
WHEN MACHINE RUNS OUT OF FUEL....18737
METHOD OF TOWING MACHINE....18738
IF BATTERY IS DISCHARGED....18743
OTHER TROUBLE....18746
MAINTENANCE....18751
GUIDES TO MAINTENANCE....18752
OUTLINES OF SERVICE....18754
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....18754
OUTLINE OF ELECTRIC SYSTEM....18757
WEAR PARTS....18758
WEAR PARTS LIST....18758
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....18759
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....18760
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....18761
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....18762
TORQUE LIST....18762
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....18763
MAINTENANCE SCHEDULE CHART....18764
MAINTENANCE SCHEDULE CHART....18764
ADJUST INJECTOR....18766
SERVICE PROCEDURE....18767
INITIAL 250 HOURS SERVICE....18767
WHEN REQUIRED....18768
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT....18768
CLEAN INSIDE OF COOLING SYSTEM....18772
CHECK WATER SEPARATOR, DRAIN WATER....18775
CHECK TRANSMISSION OIL LEVEL, ADD OIL....18776
CHECK AXLE OIL LEVEL, ADD OIL....18777
CLEAN AXLE CASE BREATHER....18778
CLEAN AIR CONDITIONER CONDENSER....18779
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID....18779
CLEAN RADIATOR FINS AND COOLER FINS....18780
CHECK ELECTRICAL INTAKE AIR HEATER....18783
TURN, REPLACE BOLT-ON CUTTING EDGE....18784
REPLACE BUCKET TEETH....18785
CHECK AIR CONDITIONER....18787
REPLACE SLOW BLOW FUSE....18788
CHECKING FUNCTION OF ACCUMULATOR....18789
SELECTION AND INSPECTION OF TIRES....18790
CHECK BEFORE STARTING....18792
EVERY 50 HOURS SERVICE....18793
DRAIN WATER, SEDIMENT FROM FUEL TANK....18793
EVERY 100 HOURS SERVICE....18794
LUBRICATE REAR AXLE PIVOT PIN....18794
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL....18794
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER....18795
EVERY 250 HOURS SERVICE....18796
CHECK BATTERY ELECTROLYTE LEVEL....18796
CHECK PARKING BRAKE....18798
CHECK ALTERNATOR BELT TENSION, ADJUST....18798
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....18799
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN....18800
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER....18800
CHECKING FUNCTION OF ACCUMULATOR....18801
LUBRICATING ....18801
EVERY 500 HOURS SERVICE....18803
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....18803
REPLACE ADDITIONAL FUEL FILTER CARTRIDGE....18804
EVERY 1000 HOURS SERVICE....18806
CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN STRAINER....18806
CLEAN TRANSMISSION CASE BREATHER....18807
LUBRICATING....18807
CHECK TIGHTENING PARTS OF TURBOCHARGER....18808
CHECK PLAY OF TURBOCHARGER ROTOR....18808
REPLACE CORROSION RESISTOR CARTRIDGE....18808
REPLACE FUEL FILTER CARTRIDGE....18809
EVERY 2000 HOURS SERVICE....18811
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT....18811
REPLACE HYDRAULIC TANK BREATHER ELEMENT....18813
CHANGE AXLE OIL....18814
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER....18814
CLEAN PPC CIRCUIT STRAINER....18815
CLEAN ENGINE BREATHER ELEMENT....18815
CHECK BRAKE DISC WEAR....18816
CHECKING FUNCTION OF ACCUMULATOR....18817
CHECK ALTERNATOR, STARTING MOTOR....18817
CHECK ENGINE VALVE CLEARANCE, ADJUST....18817
CLEAN AND CHECK TURBOCHARGER....18817
CHECK INJECTOR....18817
CHECK VIBRATION DAMPER....18817
EVERY 4000 HOURS SERVICE....18818
LUBRICATING....18818
CHECK WATER PUMP....18819
CHECK AIR CONDITIONER COMPRESSOR, ADJUST....18819
CHECK INJECTOR....18819
REPLACE INJECTOR ASSEMBLY....18819
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER....18819
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER....18820
EVERY 8000 HOURS SERVICE....18821
REPLACE INJECTOR NOZZLE TIP....18821
REPLACE HIGH-PRESSURE PIPING CLAMP....18821
REPLACE FUEL SPRAY PREVENTION CAP....18821
SPECIFICATIONS....18822
SPECIFICATIONS....18823
ATTACHMENTS, OPTIONS....18824
HANDLING LOAD METER....18825
GENERAL LOCATIONS....18825
LOAD METER FUNCTIONS....18827
HANDLING LOAD METER DISPLAY....18830
METHOD OF SETTING TIME ON CLOCK....18846
PRINTER OUTPUT....18848
HANDLING TORQUE CONVERTER LOCK-UP....18851
GENERAL LOCATIONS....18851
METHOD OF OPERATION ....18852
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED....18853
HANDLING AUTO-GREASING SYSTEM....18854
METHOD OF OPERATING AUTO-GERASING SYSTEM....18854
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM....18860
TROUBLESHOOTING....18860
HANDLING JOYSTICK STEERING SYSTEM ....18861
EXPLANATION OF COMPONENTS....18861
STRUCTURE AND FUNCTION OF JOYSTICK STEERING....18863
GETTING IN OR OUT OF OPERATOR'S CAB....18865
ADJUSTMENT OF JOYSTICK CONSOLE....18865
OPERATION METHOD OF JOYSTICK STEERING SYSTEM....18866
HANDLING EPC WORK EQUIPMENT LEVER....18869
OPERATIONAL FEATURES....18869
SWITCHES....18869
SEMI AUTO DIGGING OPERATIONS....18870
METHOD OF REMOTE POSITIONER....18872
HANDLING MULTI-FUNCTION LEVER....18874
EXPLANATION OF COMPONENTS....18874
USING FNR SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE....18878
INDEX....18880
TEN00091-03 - Wheel Loader WA470-5 Operation & Maintenance Manual....18884
COVER....18884
FOREWORD....18885
FOREWORD....18886
SAFETY INFORMATION....18887
INTRODUCTION....18889
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....18889
NECESSARY INFORMATION....18890
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....18890
ENGINE SERIAL NO. PLATE....18890
POSITION OF SERVICE METER....18891
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....18891
CONTENTS....18892
SAFETY....18895
SAFETY....18896
SAFETY LABELS....18899
LOCATION OF SAFETY LABELS....18899
SAFETY LABELS....18900
GENERAL PRECAUTIONS....18905
PRECAUTIONS FOR OPERATION....18914
STARTING ENGINE....18914
OPERATION....18916
TRANSPORTATION....18922
BATTERY....18923
TOWING....18925
PRECAUTIONS FOR MAINTENANCE....18926
PRECAUTIONS WITH TIRES....18933
OPERATION....18935
GENERAL VIEW....18936
GENERAL VIEW OF MACHINE....18936
GENERAL VIEW OF CONTROLS AND GAUGES....18937
EXPLANATION OF COMPONENTS....18940
MACHINE MONITOR....18940
SWITCHES....18970
CONTROL LEVERS, PEDALS....18984
STEERING TILT LOCK LEVER....18989
CAP WITH LOCK....18990
FRAME LOCK BAR....18992
TOWING PIN....18992
GREASE PUMP....18993
CAB DOOR OPEN LOCK....18993
CAB WINDOW OPEN LOCK CANCEL KNOB....18993
FUSE....18994
SLOW BLOW FUSE....18995
POWER OUTLET....18996
AM/FM RADIO....18997
AM/FM RADIO-CASSETTE STEREO....19003
AIR CONDITIONER....19011
HANDLING AUTO AIR CONDITIONER....19016
HANDLING CAB WIPER....19023
OPERATION....19024
CHECK BEFORE STARTING ENGINE, ADJUST....19024
STARTING ENGINE....19040
OPERATIONS AND CHECKS AFTER STARTING ENGINE....19045
STOPPING ENGINE....19047
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE....19048
TURNING....19058
OPERATION OF WORK EQUIPMENT....19060
WORK POSSIBLE USING WHEEL LOADER....19062
PRECAUTIONS FOR OPERATION....19068
ADJUSTING WORK EQUIPMENT POSTURE....19070
PARKING MACHINE....19072
CHECKS AFTER COMPLETION OF OPERATION....19074
LOCKING....19074
HANDLING THE TIRES....19075
TRANSPORTATION....19077
TRANSPORTATION PROCEDURE....19077
LOADING, UNLOADING WORK WITH TRAILERS....19077
LIFTING MACHINE....19081
COLD WEATHER OPERATION....19083
PRECAUTIONS FOR LOW TEMPERATURE....19083
PRECAUTIONS AFTER COMPLETION OF WORK....19084
AFTER COLD WEATHER....19084
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER....19085
LONG-TERM STORAGE....19086
BEFORE STORAGE....19086
DURING STORAGE....19086
AFTER STORAGE....19086
TROUBLESHOOTING....19087
WHEN MACHINE RUNS OUT OF FUEL....19087
METHOD OF TOWING MACHINE....19088
IF BATTERY IS DISCHARGED....19093
OTHER TROUBLE....19096
MAINTENANCE....19101
GUIDES TO MAINTENANCE....19102
OUTLINES OF SERVICE....19104
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....19104
OUTLINE OF ELECTRIC SYSTEM....19107
WEAR PARTS....19108
WEAR PARTS LIST....19108
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....19109
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....19110
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....19111
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....19112
TORQUE LIST....19112
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....19113
MAINTENANCE SCHEDULE CHART....19114
MAINTENANCE SCHEDULE CHART....19114
ADJUST INJECTOR....19116
SERVICE PROCEDURE....19117
INITIAL 250 HOURS SERVICE....19117
WHEN REQUIRED....19118
CHECK BEFORE STARTING....19141
EVERY 50 HOURS SERVICE....19142
EVERY 100 HOURS SERVICE....19143
EVERY 250 HOURS SERVICE....19145
EVERY 500 HOURS SERVICE....19152
EVERY 1000 HOURS SERVICE....19155
EVERY 2000 HOURS SERVICE....19160
EVERY 4000 HOURS SERVICE....19167
EVERY 8000 HOURS SERVICE....19170
SPECIFICATIONS....19171
SPECIFICATIONS....19172
ATTACHMENTS, OPTIONS....19173
HANDLING LOAD METER....19174
GENERAL LOCATIONS....19174
LOAD METER FUNCTIONS....19176
HANDLING LOAD METER DISPLAY....19179
METHOD OF SETTING TIME ON CLOCK....19194
PRINTER OUTPUT....19196
HANDLING TORQUE CONVERTER LOCK-UP....19199
GENERAL LOCATIONS....19199
METHOD OF OPERATION....19200
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED....19201
HANDLING AUTO-GREASING SYSTEM....19202
METHOD OF OPERATING AUTO-GREASING SYSTEM....19202
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM....19208
TROUBLESHOOTING....19208
HANDLING JOYSTICK STEERING SYSTEM....19209
EXPLANATION OF COMPONENTS....19209
STRUCTURE AND FUNCTION OF JOYSTICK STEERING....19211
GETTING IN OR OUT OF OPERATOR'S CAB....19213
ADJUSTMENT OF JOYSTICK CONSOLE....19213
OPERATION METHOD OF JOYSTICK STEERING SYSTEM....19214
HANDLING EPC WORK EQUIPMENT LEVER....19217
OPERATIONAL FEATURES....19217
SWITCHES....19217
SEMI AUTO DIGGING OPERATIONS....19218
METHOD OF REMOTE POSITIONER....19220
HANDLING MULTI-FUNCTION LEVER....19222
EXPLANATION OF COMPONENTS....19222
USING FNR SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE....19226
INDEX....19229
TEN00176-04 - Wheel Loader WA470-6 Operation & Maintenance Manual....19233
COVER....19233
FOREWORD....19234
BEFORE READING THIS MANUAL....19235
SAFETY INFORMATION....19238
INTRODUCTION....19239
USE OF MACHINE....19239
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....19240
NECESSARY INFORMATION....19241
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....19241
ENGINE SERIAL NO. PLATE....19241
POSITION OF SERVICE METER....19242
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....19242
CONTENTS....19243
SAFETY....19246
SAFETY....19247
SAFETY LABELS....19250
LOCATION OF SAFETY LABELS....19250
SAFETY LABELS....19251
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....19258
PRECAUTIONS BEFORE STARTING OPERATION....19258
PREPARATIONS FOR SAFE OPERATION....19258
FIRE PREVENTION....19260
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE....19261
DO NOT GET CAUGHT IN ARTICULATING PORTION....19264
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....19264
UNAUTHORIZED MODIFICATION....19264
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....19264
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....19265
PRECAUTIONS FOR OPERATION....19266
PRECAUTIONS FOR JOBSITE....19266
STARTING ENGINE....19268
OPERATION....19270
TRANSPORTATION....19277
TOWING....19278
PRECAUTIONS FOR MAINTENANCE....19279
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....19279
PRECAUTIONS FOR INSPECTION AND MAINTENANCE....19284
TIRES....19289
OPERATION....19292
GENERAL VIEW....19293
GENERAL VIEW OF MACHINE....19293
GENERAL VIEW OF CONTROLS AND GAUGES....19294
EXPLANATION OF COMPONENTS....19297
MACHINE MONITOR....19297
SWITCHES....19330
CONTROL LEVERS, PEDALS....19345
STEERING TILT LOCK LEVER....19350
CAP WITH LOCK....19350
FRAME LOCK BAR....19351
TOWING PIN....19352
GREASE PUMP....19352
OPENING, CLOSING CAB DOORS, WINDOWS....19353
BACKUP ALARM....19357
FUSE....19358
SLOW BLOW FUSE....19359
POWER OUTLET....19360
AM/FM RADIO-CASSETTE STEREO....19361
AM/FM RADIO....19369
AIR CONDITIONER....19375
HANDLING AUTO AIR CONDITIONER....19382
HANDLING CAB WIPER....19389
OPERATION....19390
CHECK BEFORE STARTING ENGINE, ADJUST....19390
STARTING ENGINE....19408
CHECKS AFTER STARTING ENGINE....19412
OPERATIONS AND CHECKS AFTER STARTING ENGINE....19413
STOPPING ENGINE....19415
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE....19416
TURNING....19425
OPERATION OF WORK EQUIPMENT....19428
WORK POSSIBLE USING WHEEL LOADER....19430
PRECAUTIONS FOR OPERATION....19436
ADJUSTING WORK EQUIPMENT POSTURE....19438
PARKING MACHINE....19440
CHECKS AFTER COMPLETION OF OPERATION....19442
LOCKING....19443
HANDLING THE TIRES....19444
TRANSPORTATION....19446
TRANSPORTATION PROCEDURE....19446
LOADING, UNLOADING WORK WITH TRAILERS....19446
LIFTING MACHINE....19450
COLD WEATHER OPERATION....19452
PRECAUTIONS FOR LOW TEMPERATURE....19452
PRECAUTIONS AFTER COMPLETION OF WORK....19453
AFTER COLD WEATHER....19453
LONG-TERM STORAGE....19454
BEFORE STORAGE....19454
DURING STORAGE....19454
AFTER STORAGE....19454
TROUBLESHOOTING....19455
WHEN MACHINE RUNS OUT OF FUEL....19455
METHOD OF TOWING MACHINE....19455
IF BATTERY IS DISCHARGED....19460
OTHER TROUBLE....19463
MAINTENANCE....19468
GUIDES TO MAINTENANCE....19469
OUTLINES OF SERVICE....19471
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....19471
OUTLINE OF ELECTRIC SYSTEM....19474
WEAR PARTS....19475
WEAR PARTS LIST....19475
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....19476
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....19477
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....19478
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....19479
TORQUE LIST....19479
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....19480
MAINTENANCE SCHEDULE CHART....19482
MAINTENANCE SCHEDULE CHART....19482
SERVICE PROCEDURE....19484
INITIAL 250 HOURS SERVICE....19484
INITIAL 1000 HOURS SERVICE....19484
WHEN REQUIRED....19485
CHECK BEFORE STARTING....19506
EVERY 50 HOURS SERVICE....19507
EVERY 100 HOURS SERVICE....19508
EVERY 250 HOURS SERVICE....19510
EVERY 500 HOURS SERVICE....19518
EVERY 1000 HOURS SERVICE....19521
EVERY 2000 HOURS SERVICE....19526
EVERY 4000 HOURS SERVICE....19532
EVERY 8000 HOURS SERVICE....19536
SPECIFICATIONS....19538
SPECIFICATIONS....19539
ATTACHMENTS, OPTIONS....19540
SELECTING BUCKET AND TIRES....19541
HANDLING TORQUE CONVERTER LOCK-UP....19542
GENERAL LOCATIONS....19542
METHOD OF OPERATION....19543
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED....19544
HANDLING JOYSTICK STEERING SYSTEM....19545
EXPLANATION OF COMPONENTS....19545
STRUCTURE AND FUNCTION OF JOYSTICK STEERING....19549
GETTING IN OR OUT OF OPERATOR'S CAB....19550
SEAT ADJUSTMENT....19551
ADJUSTMENT OF JOYSTICK CONSOLE....19553
OPERATION USING JOYSTICK LEVER AND OPERATION USING STEERING WHEEL....19554
PRECAUTIONS FOR STEERING WITH JOYSTICK....19555
OPERATION METHOD OF JOYSTICK STEERING SYSTEM....19555
HANDLING MULTI-FUNCTION LEVER....19558
EXPLANATION OF COMPONENTS....19558
USING FNR SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE....19563
HANDLING MACHINES EQUIPPED WITH KOMTRAX....19565
BASIC PRECAUTIONS....19565
INDEX....19566
TEN00294-02 - Wheel Loader WA470-6 Operation & Maintenance Manual....19570
COVER....19570
FOREWORD....19571
BEFORE READING THIS MANUAL....19572
SAFETY INFORMATION....19573
INTRODUCTION....19574
USE OF MACHINE....19574
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....19575
NECESSARY INFORMATION....19576
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....19576
ENGINE SERIAL NO. PLATE....19576
POSITION OF SERVICE METER....19577
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....19577
CONTENTS....19578
SAFETY....19583
SAFETY....19584
SAFETY LABELS....19587
LOCATION OF SAFETY LABELS....19587
SAFETY LABELS....19588
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....19595
PRECAUTIONS BEFORE STARTING OPERATION....19595
PREPARATIONS FOR SAFE OPERATION....19595
FIRE PREVENTION....19597
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE....19598
DO NOT GET CAUGHT IN ARTICULATING PORTION....19601
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....19601
UNAUTHORIZED MODIFICATION....19601
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....19601
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....19602
PRECAUTIONS FOR OPERATION....19603
PRECAUTIONS FOR JOBSITE....19603
STARTING ENGINE....19605
OPERATION....19608
TRANSPORTATION....19614
TOWING....19615
PRECAUTIONS FOR MAINTENANCE....19616
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....19616
PRECAUTIONS FOR INSPECTION AND MAINTENANCE....19620
TIRES....19625
OPERATION....19627
GENERAL VIEW....19628
GENERAL VIEW OF MACHINE....19628
GENERAL VIEW OF CONTROLS AND GAUGES....19629
EXPLANATION OF COMPONENTS....19632
MACHINE MONITOR....19632
SWITCHES....19665
CONTROL LEVERS, PEDALS....19680
STEERING TILT LOCK LEVER....19685
CAP WITH LOCK....19686
FRAME LOCK BAR....19686
TOWING PIN....19687
GREASE PUMP....19687
OPENING, CLOSING CAB DOORS, WINDOWS....19688
BACKUP ALARM....19692
FUSE....19693
SLOW BLOW FUSE....19694
POWER OUTLET....19695
AM/FM RADIO-CASSETTE STEREO....19696
AM/FM RADIO....19704
AIR CONDITIONER....19710
HANDLING AUTO AIR CONDITIONER....19717
HANDLING CAB WIPER....19724
OPERATION....19725
CHECK BEFORE STARTING ENGINE, ADJUST....19725
STARTING ENGINE....19743
CHECKS AFTER STARTING ENGINE....19747
OPERATIONS AND CHECKS AFTER STARTING ENGINE....19748
STOPPING ENGINE....19750
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE....19751
TURNING....19760
OPERATION OF WORK EQUIPMENT....19763
WORK POSSIBLE USING WHEEL LOADER....19765
PRECAUTIONS FOR OPERATION....19771
ADJUSTING WORK EQUIPMENT POSTURE....19773
PARKING MACHINE....19775
CHECKS AFTER COMPLETION OF OPERATION....19777
LOCKING....19778
HANDLING THE TIRES....19779
TRANSPORTATION....19781
TRANSPORTATION PROCEDURE....19781
LOADING, UNLOADING WORK WITH TRAILERS....19781
LIFTING MACHINE....19785
COLD WEATHER OPERATION....19787
PRECAUTIONS FOR LOW TEMPERATURE....19787
PRECAUTIONS AFTER COMPLETION OF WORK....19788
AFTER COLD WEATHER....19788
LONG-TERM STORAGE....19789
BEFORE STORAGE....19789
DURING STORAGE....19789
AFTER STORAGE....19789
TROUBLESHOOTING....19790
WHEN MACHINE RUNS OUT OF FUEL....19790
METHOD OF TOWING MACHINE....19790
IF BATTERY IS DISCHARGED....19795
OTHER TROUBLE....19798
MAINTENANCE....19803
GUIDES TO MAINTENANCE....19804
OUTLINES OF SERVICE....19806
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....19806
OUTLINE OF ELECTRIC SYSTEM....19809
WEAR PARTS....19810
WEAR PARTS LIST....19810
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....19811
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....19812
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....19813
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....19814
TORQUE LIST....19814
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....19815
MAINTENANCE SCHEDULE CHART....19817
MAINTENANCE SCHEDULE CHART....19817
SERVICE PROCEDURE....19819
INITIAL 250 HOURS SERVICE....19819
INITIAL 1000 HOURS SERVICE....19819
WHEN REQUIRED....19820
CHECK BEFORE STARTING....19844
EVERY 50 HOURS SERVICE....19845
EVERY 100 HOURS SERVICE....19846
EVERY 250 HOURS SERVICE....19848
EVERY 500 HOURS SERVICE....19856
EVERY 1000 HOURS SERVICE....19859
EVERY 2000 HOURS SERVICE....19864
EVERY 4000 HOURS SERVICE....19870
EVERY 8000 HOURS SERVICE....19874
SPECIFICATIONS....19875
SPECIFICATIONS....19876
ATTACHMENTS, OPTIONS....19877
SELECTING BUCKET AND TIRES....19878
HANDLING TORQUE CONVERTER LOCK-UP....19879
GENERAL LOCATIONS....19879
METHOD OF OPERATION....19880
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED....19881
HANDLING JOYSTICK STEERING SYSTEM....19882
EXPLANATION OF COMPONENTS....19882
STRUCTURE AND FUNCTION OF JOYSTICK STEERING....19886
GETTING IN OR OUT OF OPERATOR'S CAB....19887
SEAT ADJUSTMENT....19888
ADJUSTMENT OF JOYSTICK CONSOLE....19890
OPERATION USING JOYSTICK LEVER AND OPERATION USING STEERING WHEEL....19891
PRECAUTIONS FOR STEERING WITH JOYSTICK....19892
OPERATION METHOD OF JOYSTICK STEERING SYSTEM....19892
HANDLING MULTI-FUNCTION LEVER....19895
EXPLANATION OF COMPONENTS....19895
USING FNR SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE....19900
HANDLING LOAD METER....19902
OUTLINE OF LOAD METER....19902
PRINCIPLE OF LOAD METER MEASUREMENT....19904
POINTS TO REMEMBER TO ENSURE HIGH ACCURACY....19906
USING LOAD METER....19908
CENTRAL LUBRICATION SYSTEM....19939
OPERATING THE CENTRAL LUBRICATION SYSTEM....19939
DISPLAY AND CONTROL UNIT....19940
CHANGING THE LUBRICATION INTERVAL TIMES....19941
HANDLING WHEEL STOPPER....19942
HANDLING BATTERY DISCONNECTOR SWITCH....19943
EXPLANATION OF COMPONENTS....19943
HANDLING....19943
RADIO/CD....19945
CONTENTS....19945
OPERATING ELEMENTS....19947
IMPORTANT INFORMATION....19948
CODE THEFT PROTECTION....19949
SWITCHING THE CAR AUDIO SYSTEM ON/OFF....19951
VOLUME CONTROL....19953
ADJUSTING THE TONE....19955
SETTING THE BALANCE AND FADER....19957
RADIO OPERATION....19958
TRAFFIC INFORMATION....19964
CD PLAYER OPERATION....19965
CD CHANGER OPERATION(OPTION)....19969
RC 10 P REMOTE CONTROL UNIT(OPTION)....19972
EXTERNAL AUDIO SOURCES....19974
SPECIFICATIONS....19975
ISO CONNECTOR....19976
HANDLING MACHINES EQUIPPED WITH KOMTRAX....19977
BASIC PRECAUTIONS....19977
INDEX....19979
TEN00339-03 - Wheel Loader WA470-6 Operation & Maintenance Manual....19983
COVER....19983
FOREWORD....19984
BEFORE READING THIS MANUAL....19985
SAFETY INFORMATION....19986
INTRODUCTION....19987
USE OF MACHINE....19987
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....19988
VISIBILITY FROM OPERATOR'S SEAT....19988
NECESSARY INFORMATION....19989
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....19989
ENGINE SERIAL NO. PLATE....19989
POSITION OF SERVICE METER....19990
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....19990
CONTENTS....19991
SAFETY....19996
SAFETY....19997
SAFETY LABELS....20000
LOCATION OF SAFETY LABELS....20000
SAFETY LABELS....20001
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....20008
PRECAUTIONS BEFORE STARTING OPERATION....20008
PREPARATIONS FOR SAFE OPERATION....20008
FIRE PREVENTION....20010
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE....20011
DO NOT GET CAUGHT IN ARTICULATING PORTION....20014
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....20014
UNAUTHORIZED MODIFICATION....20014
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....20015
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....20015
PRECAUTIONS FOR OPERATION....20016
PRECAUTIONS FOR JOBSITE....20016
STARTING ENGINE....20018
OPERATION....20021
TRANSPORTATION....20027
TOWING....20028
PRECAUTIONS FOR MAINTENANCE....20029
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....20029
PRECAUTIONS FOR INSPECTION AND MAINTENANCE....20033
TIRES....20038
OPERATION....20040
GENERAL VIEW....20041
GENERAL VIEW OF MACHINE....20041
GENERAL VIEW OF CONTROLS AND GAUGES....20042
EXPLANATION OF COMPONENTS....20045
MACHINE MONITOR....20045
SWITCHES....20078
CONTROL LEVERS, PEDALS....20093
STEERING TILT LOCK LEVER....20098
CAP WITH LOCK....20099
FRAME LOCK BAR....20099
TOWING PIN....20100
GREASE PUMP....20100
OPENING, CLOSING CAB DOORS, WINDOWS....20101
BACKUP ALARM....20105
FUSE....20106
SLOW BLOW FUSE....20107
POWER OUTLET....20108
AM/FM RADIO-CASSETTE STEREO....20109
AM/FM RADIO....20117
AIR CONDITIONER....20123
HANDLING AUTO AIR CONDITIONER....20130
HANDLING CAB WIPER....20137
OPERATION....20138
CHECK BEFORE STARTING ENGINE, ADJUST....20138
STARTING ENGINE....20156
CHECKS AFTER STARTING ENGINE....20160
OPERATIONS AND CHECKS AFTER STARTING ENGINE....20161
STOPPING ENGINE....20163
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE....20164
TURNING....20173
OPERATION OF WORK EQUIPMENT....20176
WORK POSSIBLE USING WHEEL LOADER....20178
PRECAUTIONS FOR OPERATION....20184
ADJUSTING WORK EQUIPMENT POSTURE....20186
PARKING MACHINE....20188
CHECKS AFTER COMPLETION OF OPERATION....20190
LOCKING....20191
HANDLING THE TIRES....20192
TRANSPORTATION....20194
TRANSPORTATION PROCEDURE....20194
LOADING, UNLOADING WORK WITH TRAILERS....20194
LIFTING MACHINE....20198
COLD WEATHER OPERATION....20200
PRECAUTIONS FOR LOW TEMPERATURE....20200
PRECAUTIONS AFTER COMPLETION OF WORK....20201
AFTER COLD WEATHER....20201
LONG-TERM STORAGE....20202
BEFORE STORAGE....20202
DURING STORAGE....20202
AFTER STORAGE....20202
TROUBLESHOOTING....20203
WHEN MACHINE RUNS OUT OF FUEL....20203
METHOD OF TOWING MACHINE....20203
IF BATTERY IS DISCHARGED....20208
OTHER TROUBLE....20211
MAINTENANCE....20216
GUIDES TO MAINTENANCE....20217
OUTLINES OF SERVICE....20219
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....20219
OUTLINE OF ELECTRIC SYSTEM....20222
WEAR PARTS....20223
WEAR PARTS LIST....20223
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....20224
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....20225
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....20226
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....20227
TORQUE LIST....20227
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....20228
MAINTENANCE SCHEDULE CHART....20230
MAINTENANCE SCHEDULE CHART....20230
SERVICE PROCEDURE....20232
INITIAL 250 HOURS SERVICE....20232
INITIAL 1000 HOURS SERVICE....20232
WHEN REQUIRED....20233
CHECK BEFORE STARTING....20257
EVERY 50 HOURS SERVICE....20258
EVERY 100 HOURS SERVICE....20259
EVERY 250 HOURS SERVICE....20261
EVERY 500 HOURS SERVICE....20269
EVERY 1000 HOURS SERVICE....20272
EVERY 2000 HOURS SERVICE....20277
EVERY 4000 HOURS SERVICE....20283
EVERY 8000 HOURS SERVICE....20287
SPECIFICATIONS....20288
SPECIFICATIONS....20289
ATTACHMENTS, OPTIONS....20290
SELECTING BUCKET AND TIRES....20291
HANDLING TORQUE CONVERTER LOCK-UP....20292
GENERAL LOCATIONS....20292
METHOD OF OPERATION....20293
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED....20294
HANDLING JOYSTICK STEERING SYSTEM....20295
EXPLANATION OF COMPONENTS....20295
STRUCTURE AND FUNCTION OF JOYSTICK STEERING....20299
GETTING IN OR OUT OF OPERATOR'S CAB....20300
SEAT ADJUSTMENT....20301
ADJUSTMENT OF JOYSTICK CONSOLE....20303
OPERATION USING JOYSTICK LEVER AND OPERATION USING STEERING WHEEL....20304
PRECAUTIONS FOR STEERING WITH JOYSTICK....20305
OPERATION METHOD OF JOYSTICK STEERING SYSTEM....20305
HANDLING MULTI FUNCTION MONO-LEVER....20308
EXPLANATION OF COMPONENTS....20308
USING FNR SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE....20313
HANDLING LOAD METER....20315
OUTLINE OF LOAD METER....20315
PRINCIPLE OF LOAD METER MEASUREMENT....20317
POINTS TO REMEMBER TO ENSURE HIGH ACCURACY....20319
USING LOAD METER....20321
CENTRAL LUBRICATION SYSTEM....20352
OPERATING THE CENTRAL LUBRICATION SYSTEM....20352
DISPLAY AND CONTROL UNIT....20353
CHANGING THE LUBRICATION INTERVAL TIMES....20354
HANDLING WHEEL STOPPER....20355
HANDLING BATTERY DISCONNECTOR SWITCH....20356
EXPLANATION OF COMPONENTS....20356
HANDLING....20357
RADIO/CD....20358
CONTENTS....20358
OPERATING ELEMENTS....20360
IMPORTANT INFORMATION....20361
CODE THEFT PROTECTION....20362
SWITCHING THE CAR AUDIO SYSTEM ON/OFF....20364
VOLUME CONTROL....20366
ADJUSTING THE TONE....20368
SETTING THE BALANCE AND FADER....20370
RADIO OPERATION....20371
TRAFFIC INFORMATION....20377
CD PLAYER OPERATION....20378
CD CHANGER OPERATION(OPTION)....20382
RC 10 P REMOTE CONTROL UNIT(OPTION)....20385
EXTERNAL AUDIO SOURCES....20387
SPECIFICATIONS....20388
ISO CONNECTOR....20389
HANDLING MACHINES EQUIPPED WITH KOMTRAX....20390
BASIC PRECAUTIONS....20390
INDEX....20392
TEN00451-00 - Wheel Loader WA470-6 Operation & Maintenance Manual....20396
COVER....20396
FOREWORD....20397
BEFORE READING THIS MANUAL....20398
SAFETY INFORMATION....20399
INTRODUCTION....20400
USE OF MACHINE....20400
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....20401
VISIBILITY FROM OPERATOR'S SEAT....20401
NECESSARY INFORMATION....20402
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....20402
ENGINE SERIAL NO. PLATE....20402
POSITION OF SERVICE METER....20403
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....20403
CONTENTS....20404
SAFETY....20409
SAFETY....20410
SAFETY LABELS....20413
LOCATION OF SAFETY LABELS....20413
SAFETY LABELS....20414
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....20421
PRECAUTIONS BEFORE STARTING OPERATION....20421
PREPARATIONS FOR SAFE OPERATION....20421
FIRE PREVENTION....20423
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE....20424
DO NOT GET CAUGHT IN ARTICULATING PORTION....20427
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....20427
UNAUTHORIZED MODIFICATION....20427
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....20428
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....20428
PRECAUTIONS FOR OPERATION....20429
PRECAUTIONS FOR JOBSITE....20429
STARTING ENGINE....20431
OPERATION....20434
TRANSPORTATION....20440
TOWING....20441
PRECAUTIONS FOR MAINTENANCE....20442
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....20442
PRECAUTIONS FOR INSPECTION AND MAINTENANCE....20446
TIRES....20451
OPERATION....20453
GENERAL VIEW....20454
GENERAL VIEW OF MACHINE....20454
GENERAL VIEW OF CONTROLS AND GAUGES....20455
EXPLANATION OF COMPONENTS....20458
MACHINE MONITOR....20458
SWITCHES....20491
CONTROL LEVERS, PEDALS....20506
STEERING TILT LOCK LEVER....20511
CAP WITH LOCK....20512
FRAME LOCK BAR....20512
TOWING PIN....20513
GREASE PUMP....20513
OPENING, CLOSING CAB DOORS, WINDOWS....20514
BACKUP ALARM....20518
FUSE....20519
SLOW BLOW FUSE....20520
POWER OUTLET....20521
AM/FM RADIO-CASSETTE STEREO....20522
AM/FM RADIO....20530
AIR CONDITIONER....20536
HANDLING AUTO AIR CONDITIONER....20543
HANDLING CAB WIPER....20550
OPERATION....20551
CHECK BEFORE STARTING ENGINE, ADJUST....20551
STARTING ENGINE....20570
CHECKS AFTER STARTING ENGINE....20574
OPERATIONS AND CHECKS AFTER STARTING ENGINE....20575
STOPPING ENGINE....20577
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE....20578
TURNING....20587
OPERATION OF WORK EQUIPMENT....20590
WORK POSSIBLE USING WHEEL LOADER....20592
PRECAUTIONS FOR OPERATION....20598
ADJUSTING WORK EQUIPMENT POSTURE....20600
PARKING MACHINE....20602
CHECKS AFTER COMPLETION OF OPERATION....20604
LOCKING....20605
HANDLING THE TIRES....20606
TRANSPORTATION....20608
TRANSPORTATION PROCEDURE....20608
LOADING, UNLOADING WORK WITH TRAILERS....20608
LIFTING MACHINE....20612
COLD WEATHER OPERATION....20614
PRECAUTIONS FOR LOW TEMPERATURE....20614
PRECAUTIONS AFTER COMPLETION OF WORK....20615
AFTER COLD WEATHER....20615
LONG-TERM STORAGE....20616
BEFORE STORAGE....20616
DURING STORAGE....20616
AFTER STORAGE....20616
TROUBLESHOOTING....20617
WHEN MACHINE RUNS OUT OF FUEL....20617
METHOD OF TOWING MACHINE....20617
IF BATTERY IS DISCHARGED....20622
OTHER TROUBLE....20625
MAITENANCE....20631
GUIDES TO MAINTENANCE....20632
OUTLINES OF SERVICE....20634
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....20634
OUTLINE OF ELECTRIC SYSTEM....20637
WEAR PARTS....20638
WEAR PARTS LIST....20638
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....20639
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....20640
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....20641
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....20642
TORQUE LIST....20642
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....20643
MAINTENANCE SCHEDULE CHART....20645
MAINTENANCE SCHEDULE CHART....20645
SERVICE PROCEDURE....20647
INITIAL 250 HOURS SERVICE....20647
INITIAL 1000 HOURS SERVICE....20647
WHEN REQUIRED....20648
CHECK BEFORE STARTING....20672
EVERY 50 HOURS SERVICE....20673
EVERY 100 HOURS SERVICE....20674
EVERY 250 HOURS SERVICE....20676
EVERY 500 HOURS SERVICE....20684
EVERY 1000 HOURS SERVICE....20687
EVERY 2000 HOURS SERVICE....20692
EVERY 4000 HOURS SERVICE....20698
EVERY 8000 HOURS SERVICE....20702
SPECIFICATIONS....20703
SPECIFICATIONS....20704
ATTACHMENTS, OPTIONS....20705
SELECTING BUCKET AND TIRES....20706
HANDLING TORQUE CONVERTER LOCK-UP....20707
GENERAL LOCATIONS....20707
METHOD OF OPERATION....20708
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED....20709
HANDLING JOYSTICK STEERING SYSTEM....20710
EXPLANATION OF COMPONENTS....20710
STRUCTURE AND FUNCTION OF JOYSTICK STEERING....20714
GETTING IN OR OUT OF OPERATOR'S CAB....20715
SEAT ADJUSTMENT....20716
ADJUSTMENT OF JOYSTICK CONSOLE....20718
OPERATION USING JOYSTICK LEVER AND OPERATION USING STEERING WHEEL....20719
PRECAUTIONS FOR STEERING WITH JOYSTICK....20720
OPERATION METHOD OF JOYSTICK STEERING SYSTEM....20720
HANDLING MULTI FUNCTION MONO-LEVER....20723
EXPLANATION OF COMPONENTS....20723
USING FNR SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE....20728
HANDLING LOAD METER....20730
OUTLINE OF LOAD METER....20730
PRINCIPLE OF LOAD METER MEASUREMENT....20732
POINTS TO REMEMBER TO ENSURE HIGH ACCURACY....20734
USING LOAD METER....20736
CENTRAL LUBRICATION SYSTEM....20767
OPERATING THE CENTRAL LUBRICATION SYSTEM....20767
DISPLAY AND CONTROL UNIT....20768
CHANGING THE LUBRICATION INTERVAL TIMES....20769
HANDLING WHEEL STOPPER....20770
HANDLING BATTERY DISCONNECTOR SWITCH....20771
EXPLANATION OF COMPONENTS....20771
HANDLING....20772
RADIO/CD....20773
CONTENTS....20773
OPERATING ELEMENTS....20775
IMPORTANT INFORMATION....20776
CODE THEFT PROTECTION....20777
SWITCHING THE CAR AUDIO SYSTEM ON/OFF....20779
VOLUME CONTROL....20781
ADJUSTING THE TONE....20783
SETTING THE BALANCE AND FADER....20785
RADIO OPERATION....20786
TRAFFIC INFORMATION....20792
CD PLAYER OPERATION....20793
CD CHANGER OPERATION(OPTION)....20797
RC 10 P REMOTE CONTROL UNIT(OPTION)....20800
EXTERNAL AUDIO SOURCES....20802
SPECIFICATIONS....20803
ISO CONNECTOR....20804
HANDLING MACHINES EQUIPPED WITH KOMTRAX....20805
BASIC PRECAUTIONS....20805
INDEX....20807
TEN00602-01 - Wheel Loader WA470-7 Operation & Maintenance Manual....20811
COVER....20811
FOREWORD ....20812
BEFORE READING THIS MANUAL ....20813
SAFETY INFORMATION ....20814
INTRODUCTION ....20815
USE OF MACHINE ....20815
DIRECTIONS OF MACHINE ....20815
PRODUCT INFORMATION ....20816
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ....20816
EPA REGULATIONS, ENGINE NUMBER PLATE ....20816
SERVICE METER LOCATION ....20817
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ....20817
CONTENTS ....20818
SAFETY ....20822
SAFETY ....20823
SAFETY LABELS ....20825
LOCATION OF SAFETY LABELS ....20825
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ....20834
PRECAUTIONS BEFORE STARTING OPERATION ....20834
PREPARATIONS FOR SAFE OPERATION ....20835
FIRE PREVENTION ....20837
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE ....20839
DO NOT GET CAUGHT IN WORK EQUIPMENT ....20842
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ....20842
UNAUTHORIZED MODIFICATION ....20842
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ....20843
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ....20843
PRECAUTIONS FOR OPERATION ....20844
PRECAUTIONS FOR JOBSITE ....20844
STARTING ENGINE ....20847
OPERATION ....20850
TRANSPORTATION ....20856
TOWING ....20857
PRECAUTIONS FOR MAINTENANCE ....20858
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ....20858
PRECAUTIONS FOR INSPECTION AND MAINTENANCE ....20863
TIRES ....20867
OPERATION ....20868
GENERAL VIEW ....20869
GENERAL VIEW OF MACHINE ....20869
GENERAL VIEW OF CONTROLS AND GAUGES ....20871
SWITCH PANEL ....20872
MACHINE MONITOR ....20873
EXPLANATION OF COMPONENTS ....20875
MACHINE MONITOR ....20875
SWITCHES ....20947
CONTROL LEVERS AND PEDALS ....20961
OIL FILLER CAP ....20967
ASHTRAY ....20969
FRAME LOCK BAR ....20970
TOWING PIN ....20971
GREASE PUMP HOLDER ....20972
BATTERY DISCONNECT SWITCH ....20973
SYSTEM OPERATING LAMP ....20975
BACKUP ALARM ....20976
OPEN AND CLOSE CAB DOOR ....20977
FUSE ....20981
SLOW BLOW FUSE ....20983
AUXILIARY ELECTRIC POWER ....20984
OPTIONAL POWER SUPPLY OUTLET ....20985
HANDLING RADIO ....20986
HANDLING AUTO AIR CONDITIONER ....20991
HANDLING FRONT WIPER ....21002
FIRE EXTINGUISHER ....21003
HANDLING REAR VIEW MONITOR ....21004
HANDLING Komatsu Diesel Particulate Filter (KDPF) ....21005
HANDLING Komatsu Closed Crankcase Ventilation (KCCV) ....21013
HANDLING MACHINES EQUIPPED WITH KOMTRAX ....21014
MACHINE OPERATIONS AND CONTROLS ....21016
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ....21016
STARTING ENGINE ....21039
CHECKS AFTER STARTING ENGINE ....21044
STOPPING ENGINE ....21047
MACHINE OPERATION ....21048
STEERING MACHINE ....21058
WORK EQUIPMENT CONTROLS AND OPERATIONS ....21062
RECOMMENDED APPLICATIONS ....21064
RULES FOR OPERATION ....21070
BUCKET LEVEL INDICATOR ....21072
REMOTE POSITIONER ....21073
PARKING MACHINE ....21077
CHECK AFTER FINISHING WORK ....21079
LOCKING ....21080
HANDLING TIRES ....21081
TRANSPORTATION ....21083
TRANSPORTATION PROCEDURE ....21083
LOADING AND UNLOADING WITH TRAILER ....21084
LIFTING MACHINE ....21088
COLD WEATHER OPERATION ....21090
COLD WEATHER OPERATION INFORMATION ....21090
AFTER DAILY WORK COMPLETION ....21091
IN COLD AREAS ....21091
AFTER COLD WEATHER SEASON ....21091
LONG-TERM STORAGE ....21092
BEFORE STORAGE ....21092
DURING STORAGE ....21092
AFTER STORAGE ....21093
STARTING MACHINE AFTER LONG-TERM STORAGE ....21093
TROUBLES AND ACTIONS ....21094
RUNNING OUT OF FUEL ....21094
TOWING MACHINE ....21095
DISCHARGED BATTERY ....21100
OTHER TROUBLE ....21104
MAINTENANCE ....21110
RULES FOR MAINTENANCE ....21111
SERVICE METER READING ....21111
KOMATSU GENUINE REPLACEMENT PARTS ....21111
KOMATSU GENUINE LUBRICANTS ....21111
ALWAYS USE CLEAN WASHER FLUID ....21111
FRESH AND CLEAN LUBRICANTS ....21111
CHECK DRAINED OIL AND USED FILTER ....21111
CAUTION FOR REFILLING OIL OR FUEL ....21111
WELDING INSTRUCTIONS ....21111
DO NOT DROP THINGS INSIDE MACHINE ....21111
PRECAUTIONS FOR KDPF ....21111
DUSTY JOBSITES ....21111
AVOID MIXING OIL ....21112
LOCKING INSPECTION COVERS ....21112
BLEEDING AIR FROM HYDRAULIC CIRCUIT ....21112
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ....21112
CHECKS AFTER INSPECTION AND MAINTENANCE ....21112
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE ....21112
CLOSE ENGINE SIDE COVER SECURELY ....21112
OUTLINE OF MAINTENANCE ....21113
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ....21113
HANDLING ELECTRICAL COMPONENTS ....21117
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS ....21118
TIGHTENING TORQUE LIST ....21118
MAINTENANCE SCHEDULE ....21119
MAINTENANCE SCHEDULE TABLE ....21119
MAINTENANCE PROCEDURE ....21121
EVERY 10 HOURS MAINTENANCE (ONLY FOR THE FIRST 50 HOURS) ....21121
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ....21121
WHEN REQUIRED ....21122
CHECKS BEFORE STARTING ....21145
EVERY 50 HOURS MAINTENANCE ....21146
EVERY 100 HOURS MAINTENANCE ....21147
EVERY 250 HOURS MAINTENANCE ....21149
EVERY 500 HOURS MAINTENANCE ....21158
EVERY 1000 HOURS MAINTENANCE ....21161
EVERY 2000 HOURS MAINTENANCE ....21166
EVERY 4000 HOURS MAINTENANCE ....21176
EVERY 4500 HOURS MAINTENANCE ....21179
EVERY 8000 HOURS MAINTENANCE ....21181
EVERY 9000 HOURS MAINTENANCE ....21182
SPECIFICATIONS ....21184
SPECIFICATIONS ....21185
ATTACHMENTS AND OPTIONS ....21188
TIRE AND BUCKET SELECTION ....21189
HANDLING JOYSTICK STEERING SYSTEM ....21190
EXPLANATION OF COMPONENTS ....21190
FUNCTION AND STRUCTURE OF JOYSTICK STEERING ....21196
PRECAUTIONS WHEN HANDLING JOYSTICK STEERING ....21197
OPERATION METHOD OF JOYSTICK STEERING ....21198
GETTING ON OR OFF MACHINE ....21201
ADJUST JOYSTICK CONSOLE ....21202
HANDLING MULTI-FUNCTION LEVER ....21208
NAME OF EACH PART ....21208
REPLACEMENT PARTS ....21216
SAFETY CRITICAL PARTS ....21217
SAFETY CRITICAL PARTS LIST ....21217
CONSUMABLE PARTS ....21218
CONSUMABLE PARTS LIST ....21218
RECOMMENDED FUEL, COOLANT, AND LUBRICANT ....21219
LUBRICATION CHART ....21219
LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE AND RECOMMENDED GENUINE LUBRICANTS ....21222
RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL ....21224
INDEX ....21226
VEAM946100 - Wheel Loader WA470-6 Operation & Maintenance Manual....21230
1. Foreword....21232
1.1 Foreword....21233
1.1.1 EU Directives....21234
1.2 Safety information....21235
1.2.1 Signal words....21235
1.2.2 Safety labels....21237
1.3 Introduction....21238
1.3.1 Intended use....21238
1.3.2 Directions of machine....21239
1.3.3 Visibility from operator's seat....21239
1.4 Necessary information....21241
1.4.1 Product Identification Number (PIN)/Machine serial no. plate and position....21241
1.4.2 Engine serial no. plate and position....21241
1.4.3 ROPS/FOPS-Cab serial no. plate....21242
1.4.4 Axle serial no. plate....21242
1.4.5 Transmission serial no. plate....21242
1.4.6 Seat operator serial no. plate....21243
1.4.7 Position of service meter....21243
1.4.8 Table to enter serial no. and distributor....21243
1.5 Contents....21244
1.6 Dimensions, weights and operating data....21252
1.6.1 WA470-6H: Dimensions, weights and operating data....21252
1.7 CE-Conforming equipment....21253
1.7.1 CE-Conforming equipment....21253
1.7.2 Manufacturer-supplied CE-Conforming equipment, according to document 419-93-H1250....21254
2. Safety....21258
2.1 Safety labels....21259
2.1.1 Location of safety labels....21259
2.1.2 Presentation of safety labels....21260
2.2 General precautions....21264
2.3 Precautions for operation....21277
2.3.1 Starting engine....21277
2.3.2 Operation....21279
2.3.3 Transportation....21286
2.3.4 Battery....21288
2.3.5 Towing....21290
2.4 Precautions for maintenance....21291
2.5 Precautions with tires....21300
3. Operation....21302
3.1 General view....21303
3.1.1 General view of machine....21303
3.1.2 General view of controls and gauges....21304
3.2 Explanation of components....21308
3.2.1 Machine monitor....21308
Types of warning....21309
Central warning lamp....21310
Character display portion....21311
Emergency stop item....21317
Caution items....21320
Inspection and maintenance item....21323
Pilot display portion....21327
Meter display portion....21333
Other functions of machine monitor....21336
3.2.2 Switches....21341
3.2.3 Control levers, pedals....21357
3.2.4 Steering tilt lock lever....21364
3.2.5 Cap with lock....21365
3.2.6 Safety bar....21366
3.2.7 Towing pin....21367
3.2.8 Grease pump....21367
3.2.9 Cab door....21368
3.2.10 Cab door open lock....21368
3.2.11 Cab window open lock....21369
Cab left window open lock reset knob....21369
Cab right window open lock reset knob....21369
Reset right window open lock for escape....21369
3.2.12 Backup alarm....21370
3.2.13 Fuse....21371
Fuse capacity and name of circuit....21371
3.2.14 Slow blow fuse....21372
3.2.15 Power outlet....21373
3.2.16 Air conditioner (standard)....21374
General locations and function of control panel....21374
Method of operation....21377
Precautions when using....21379
Precautions for inspection and maintenance....21379
Cool box....21380
3.2.17 Air conditioner (automatic)....21381
General locations and function of control panel....21381
Method of operation....21385
Precautions when using....21387
Precautions for inspection and maintenance....21387
3.2.18 Handling cab wiper....21388
Preventing damage to wiper arm bracket....21388
3.3 Operation....21389
3.3.1 Check before starting engine, adjust....21389
Walk-around check....21389
Check before starting....21392
Adjustment....21400
Safety belt....21401
Adjust lever stand....21402
Adjusting mirrors....21403
Operations and checks before starting engine....21404
3.3.2 Starting engine....21406
Normal starting....21406
Starting in cold weather....21408
Automatic warming-up operation....21410
3.3.3 Operations and checks after starting engine....21411
Breaking-in the machine....21411
Normal operation....21412
3.3.4 Stopping engine....21414
3.3.5 Check after stopping engine....21414
3.3.6 Moving the machine (directional, speed), stopping the machine....21415
Preparations for moving the machine....21415
Changing gear speed....21418
Changing direction....21419
Using switch to change between forward and reverse....21421
Stopping the machine....21423
Transmission cut-off function....21424
3.3.7 Turning....21426
Emergency steering....21427
3.3.8 Operation of work equipment....21429
Lift arm operation....21430
Bucket operation....21430
3.3.9 Work possible using wheel loader....21431
Digging operations....21431
Leveling operation....21435
Pushing operation....21435
Load and carry operations....21435
Loading operations....21436
3.3.10 Precautions for operation....21438
Permissible water depth....21438
If wheel brake does not work....21438
Precautions when driving up or down slopes....21438
3.3.11 Adjusting work equipment posture....21441
Adjusting boom kickout....21441
Adjusting bucket positioner....21442
Bucket level indicator....21442
3.3.12 Parking machine....21443
3.3.13 Checks after completion of operation....21445
Before stopping engine....21445
After stopping engine....21445
3.3.14 Locking....21446
3.3.15 Handling the tires....21447
Precautions when handling tires....21447
Tire pressure....21447
Precautions for using load and carry method....21449
3.4 Transportation....21450
3.4.1 Transportation procedure....21450
3.4.2 Loading, unloading work with trailers....21450
Loading....21451
Securing machine....21451
Unloading....21453
3.4.3 Lifting machine....21454
Location of lifting position mark....21455
Weight table....21455
Lifting procedure....21456
3.5 Cold weather operation....21457
3.5.1 Precautions for low temperature....21457
Fuel and lubricants....21457
Coolant....21457
Battery....21458
3.5.2 Precautions after completion of work....21459
3.5.3 After cold weather....21459
3.5.4 Warming-up operation for steering hydraulic circuit in cold weather....21460
3.6 Long-term storage....21461
3.6.1 Before storage....21461
3.6.2 During storage....21461
3.6.3 After storage....21462
3.7 Troubleshooting....21463
3.7.1 When machine runs out of fuel....21463
3.7.2 Towing the machine....21463
When engine can be used....21466
When engine cannot be used....21466
Releasing parking brake....21467
Emergency travel operation....21469
3.7.3 If battery is discharged....21470
Removal and installation of battery....21471
Precautions for charging battery....21471
Starting engine with booster cable....21472
3.7.4 Other trouble....21474
Electrical system....21474
Chassis....21475
Engine....21477
4. Maintenance....21480
4.1 Guides to maintenance....21481
4.2 Outlines of service....21485
4.2.1 Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis)....21486
Oil....21486
Fuel....21487
Coolant and water for dilution....21488
Grease....21489
Carrying out KOWA (KOMATSU Oil Wear Analysis)....21489
Storing oil and fuel....21491
Filters....21491
4.2.2 Outline of electric system....21492
4.3 Wear parts....21493
4.3.1 Wear parts list....21493
4.4 Fuel, coolant and lubricants....21495
4.4.1 Lubrication chart....21497
4.4.2 Use of fuel, coolant and lubricants according to ambient temperature....21498
4.4.3 Recommended brands, recommended quality for products other than KOMATSU genuine oil....21501
4.5 Standard tightening torques for bolts and nuts....21502
4.5.1 Torque list....21502
4.6 Periodic replacement of safety critical parts....21504
4.7 Maintenance schedule chart....21506
4.7.1 Maintenance schedule chart....21506
4.8 Replace injector assembly....21509
4.9 Service procedure....21510
4.9.1 Initial 50 hours service (only after the first 50 hours)....21510
Check for loose wheel hub bolts, tighten....21510
4.9.2 Initial 250 hours service (only after the first 250 hours)....21510
Replace transmission oil filter cartridge....21510
Replace hydraulic tank filter element....21510
4.9.3 Initial 1000 hours service (only after the first 1000 hours)....21510
Check engine valve clearance, adjust....21510
4.9.4 When required....21511
Clean, replace air cleaner element....21511
Clean inside of cooling system....21514
Check transmission oil level, add oil....21518
Check axle oil level, add oil....21519
Clean axle case breather....21520
Clean air conditioner condenser....21521
Check window washing fluid level, add fluid....21522
Clean radiator fins and cooler fins....21522
Turn, replace bolt on cutting edge....21526
Replace bucket teeth....21527
Check air conditioner....21528
Replace slow blow fuse....21530
Checking function of accumulator....21531
Selection and inspection of tires....21532
4.9.5 Check before starting....21534
Check before starting....21534
4.9.6 Every 50 hours service....21534
Drain water, sediment from fuel tank....21534
4.9.7 Every 100 hours service....21535
Lubricate rear axle pivot pin....21535
Check oil level in hydraulic tank, add oil....21535
Clean element in air conditioner fresh air filter....21536
4.9.8 Every 250 hours service....21537
Check battery electrolyte level....21537
Check parking brake....21540
Check alternator belt tension, adjust....21540
Check air conditioner compressor belt tension, adjust....21542
Check for loose wheel hub bolts, tighten....21544
Clean element in air conditioner recirculation filter....21544
Checking function of accumulator....21545
Lubricating....21546
4.9.9 Every 500 hours service....21547
Change oil in engine oil pan, replace engine oil filter cartridge....21547
Replace fuel pre-filter cartridge....21549
4.9.10 Every 1000 hours service....21551
Replace fuel main filter cartridge....21551
Change oil in transmission case and transmission oil filter cartridge, clean strainer....21553
Clean transmission case breather....21554
Lubricating....21555
Check of engine air intake piping clamps for looseness....21555
Replace corrosion resistor cartridge....21555
4.9.11 Every 2000 hours service....21556
Change oil in hydraulic tank, replace hydraulic filter element....21556
Replace hydraulic tank breather element....21559
Change axle oil....21560
Replace element in air conditioner recirculation air filter, fresh air filter....21561
Check brake disc wear....21561
Checking function of accumulator....21563
Check alternator....21564
Check engine valve clearance, adjust....21564
Check vibration damper....21564
4.9.12 Every 4000 hours service....21565
Lubricating....21565
Check water pump....21566
Check air conditioner compressor, adjust....21566
Check for loose engine high-pressure piping clamps, hardening of rubber....21567
Checking for missing fuel spray prevention cap, hardening of rubber....21567
Check starting motor....21568
4.9.13 Every 8000 hours service....21568
Replace high-pressure piping clamp....21568
Replace fuel spray prevention cap....21568
4.9.14 Every 12000 hours service....21568
Replace injector assembly....21568
5. Technical Data....21570
5.1 Technical data....21571
5.2 Noise emission levels....21573
5.3 Vibration level....21574
5.4 Limit values for slopes....21576
6. Attachments, Options....21578
6.1 Selecting bucket and tires....21579
6.2 Handling torque converter lock-up....21580
6.2.1 General locations....21581
6.2.2 Method of operation....21583
6.2.3 Warning/limit functions for travel speed....21584
Travel speed warning function....21584
Travel speed limit function....21584
6.3 Handling machines equipped with KOMTRAX....21585
6.3.1 Basic precautions....21586
6.4 Joystick steering system....21587
6.4.1 Components....21587
6.4.2 Structure and function....21590
Operation using joystick lever and operation using steering wheel....21591
Getting in or out....21592
Adjustment of joystick console....21593
6.4.3 Operation method of joystick steering system....21594
6.5 Multi-function lever (with/without auxiliary control lever)....21597
6.5.1 Explanation of components....21597
6.5.2 Operation....21602
Using switch to change between forward and reverse....21602
6.6 3-lever control....21604
6.6.1 Explanation of components....21604
6.7 Central lubrication system....21607
6.7.1 Operating the central lubrication system....21607
6.7.2 Display and control unit....21607
LED-display....21608
Pushbuttons....21608
6.7.3 Changing the lubrication interval times....21609
7. Index....21610
7.1 Index....21611
8. Notes....21616
VEAM946102 - Wheel Loader WA470-6 Operation & Maintenance Manual....21622
1. Foreword....21624
1.1 Foreword....21625
EU Directives....21626
1.2 Safety information....21627
1.2.1 Signal words....21627
1.2.2 Safety labels....21629
1.3 Introduction....21630
1.3.1 Intended use....21630
1.3.2 Directions of machine....21631
1.3.3 Visibility from operator's seat....21631
1.4 Necessary information....21633
1.4.1 Product Identification Number (PIN)/Machine serial no. plate and position....21633
1.4.2 Engine serial no. plate and position....21634
1.4.3 ROPS/FOPS-Cab serial no. plate....21634
1.4.4 Axle serial no. plate....21635
1.4.5 Transmission serial no. plate....21635
1.4.6 Seat operator serial no. plate....21636
1.4.7 Position of service meter....21636
1.4.8 Table to enter serial no. and distributor....21637
1.4.9 Declaration of conformity (for machines placed on the market as from 29th December 2009)....21637
1.5 Contents....21638
1.6 Dimensions, weights and operating data....21646
1.6.1 WA470-6: Dimensions, weights and operating data....21646
1.7 CE-Conforming equipment....21647
1.7.1 CE-Conforming equipment....21647
1.7.2 Manufacturer-supplied CE-Conforming equipment, according to document 419-93-H1250....21648
2. Safety....21652
2.1 Safety labels....21653
2.1.1 Location of safety labels....21653
2.1.2 Presentation of safety labels....21654
2.2 General precautions....21659
2.3 Precautions for operation....21672
2.3.1 Starting engine....21672
2.3.2 Operation....21674
2.3.3 Transportation....21681
2.3.4 Battery....21683
2.3.5 Towing....21686
2.4 Precautions for maintenance....21687
2.5 Precautions with tires....21697
3. Operation....21700
3.1 General view....21701
3.1.1 General view of machine....21701
3.1.2 General view of controls and gauges....21702
3.2 Explanation of components....21706
3.2.1 Machine monitor....21706
Types of warning....21707
Central warning lamp....21708
Character display portion....21709
Emergency stop item....21716
Caution items....21719
Inspection and maintenance item....21722
Pilot display portion....21726
Meter display portion....21732
Other functions of machine monitor....21735
3.2.2 Switches....21741
3.2.3 Control levers, pedals....21758
3.2.4 Steering tilt lock lever....21765
3.2.5 Cap with lock....21766
3.2.6 Safety bar....21767
3.2.7 Towing pin....21768
3.2.8 Grease pump....21768
3.2.9 Cab door....21769
3.2.10 Cab door open lock....21769
3.2.11 Cab window open lock....21770
Cab left window open lock reset knob....21770
Cab right window open lock reset knob....21770
Reset right window open lock for escape....21770
3.2.12 Backup alarm....21771
3.2.13 Fuse....21771
Fuse capacity and name of circuit....21772
3.2.14 Slow blow fuse....21773
3.2.15 Location and presentation of relays....21774
3.2.16 Power outlet....21775
3.2.17 Air conditioner (standard)....21776
General locations and function of control panel....21776
Method of operation....21779
Precautions when using....21781
Precautions for inspection and maintenance....21781
Cool box....21782
3.2.18 Air conditioner (automatic)....21783
General locations and function of control panel....21783
Method of operation....21787
Precautions when using....21789
Precautions for inspection and maintenance....21789
3.2.19 Handling cab wiper....21790
Preventing damage to wiper arm bracket....21790
3.3 Operation....21791
3.3.1 Check before starting engine, adjust....21791
Walk-around check....21791
Check before starting....21794
Adjustment....21802
Safety belt....21803
Adjust lever stand....21804
Adjusting mirrors....21805
Operations and checks before starting engine....21806
3.3.2 Starting engine....21808
Normal starting....21808
Ambient temperature range for operation and storage....21810
Starting in cold weather....21811
Automatic warming-up operation....21813
3.3.3 Operations and checks after starting engine....21814
Breaking-in the machine....21814
Normal operation....21815
3.3.4 Stopping engine....21817
3.3.5 Check after stopping engine....21817
3.3.6 Moving the machine (directional, speed), stopping the machine....21818
Preparations for moving the machine....21818
Changing gear speed....21821
Changing direction....21822
Using switch to change between forward and reverse....21824
Stopping the machine....21826
Transmission cut-off function....21827
3.3.7 Turning....21829
Emergency steering....21830
3.3.8 Operation of work equipment....21832
Lift arm operation....21833
Bucket operation....21833
3.3.9 Work possible using wheel loader....21834
Digging operations....21834
Leveling operation....21838
Pushing operation....21838
Load and carry operations....21838
Loading operations....21839
3.3.10 Precautions for operation....21841
Permissible water depth....21841
If wheel brake does not work....21841
Precautions when driving up or down slopes....21841
3.3.11 Adjusting work equipment posture....21844
Adjusting boom kickout....21844
Adjusting bucket positioner....21845
Bucket level indicator....21845
3.3.12 Parking machine....21846
3.3.13 Checks after completion of operation....21848
Before stopping engine....21848
After stopping engine....21848
3.3.14 Locking....21849
3.3.15 Handling the tires....21850
Precautions when handling tires....21850
Tire pressure....21850
Precautions for using load and carry method....21852
3.4 Transportation....21853
3.4.1 Transportation procedure....21853
Ensure machine stability....21853
3.4.2 Loading, unloading work with trailers....21853
Loading....21854
Securing machine....21854
Unloading....21856
3.4.3 Lifting machine....21857
Location of lifting position mark....21858
Lifting procedure....21859
3.5 Cold weather operation....21860
3.5.1 Precautions for low temperature....21860
Fuel and lubricants....21860
Coolant....21860
Battery....21861
3.5.2 Precautions after completion of work....21862
3.5.3 After cold weather....21862
3.5.4 Warming-up operation for steering hydraulic circuit in cold weather....21863
3.6 Long-term storage....21864
3.6.1 Before storage....21864
3.6.2 During storage....21864
3.6.3 After storage....21866
3.7 Troubleshooting....21867
3.7.1 When machine runs out of fuel....21867
3.7.2 Towing the machine....21867
When engine can be used....21870
When engine cannot be used....21870
Releasing parking brake....21871
Emergency travel operation....21873
3.7.3 If battery is discharged....21874
Removal and installation of battery....21875
Precautions for charging battery....21875
Starting engine with booster cable....21876
3.7.4 Other trouble....21879
Electrical system....21879
Chassis....21880
Engine....21882
4. Maintenance....21884
4.1 Guides to maintenance....21885
4.2 Outlines of service....21889
4.2.1 Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis)....21890
Oil....21890
Fuel....21891
Coolant and water for dilution....21892
Grease....21893
Carrying out KOWA (KOMATSU Oil Wear Analysis)....21893
Storing oil and fuel....21895
Filters....21895
4.2.2 Outline of electric system....21896
4.3 Wear parts....21897
4.3.1 Wear parts list....21897
4.4 Fuel, coolant and lubricants....21899
4.4.1 Lubrication chart....21901
4.4.2 Use of fuel, coolant and lubricants according to ambient temperature....21902
4.4.3 Recommended brands, recommended quality for products other than KOMATSU genuine oil....21904
4.5 Standard tightening torques for bolts and nuts....21905
4.5.1 Torque list....21905
4.6 Periodic replacement of safety critical parts....21907
4.7 Maintenance schedule chart....21909
4.7.1 Maintenance schedule chart....21909
4.8 Replace injector assembly....21912
4.9 Service procedure....21913
4.9.1 Initial 50 hours service (only after the first 50 hours)....21913
Check for loose wheel hub bolts, tighten....21913
4.9.2 Initial 250 hours service (only after the first 250 hours)....21913
Replace transmission oil filter cartridge....21913
Replace hydraulic tank filter element....21913
4.9.3 Initial 1000 hours service (only after the first 1000 hours)....21913
Check engine valve clearance, adjust....21913
4.9.4 When required....21914
Clean, replace air cleaner element....21914
Clean inside of cooling system....21917
Check transmission oil level, add oil....21921
Check axle oil level, add oil....21922
Clean axle case breather....21923
Clean air conditioner condenser....21924
Check window washing fluid level, add fluid....21925
Clean radiator fins and cooler fins....21925
Turn, replace bolt on cutting edge....21929
Replace bucket teeth....21930
Check air conditioner....21931
Replace slow blow fuse....21933
Checking function of accumulator....21934
Selection and inspection of tires....21935
4.9.5 Check before starting....21937
Check before starting....21937
4.9.6 Every 50 hours service....21937
Drain water, sediment from fuel tank....21937
4.9.7 Every 100 hours service....21938
Lubricate rear axle pivot pin....21938
Check oil level in hydraulic tank, add oil....21938
Clean element in air conditioner fresh air filter....21939
4.9.8 Every 250 hours service....21940
Check battery electrolyte level....21940
Check parking brake....21943
Check alternator belt tension, adjust....21943
Check air conditioner compressor belt tension, adjust....21945
Check for loose wheel hub bolts, tighten....21947
Clean element in air conditioner recirculation filter....21947
Checking function of accumulator....21948
Lubricating....21949
4.9.9 Every 500 hours service....21950
Change oil in engine oil pan, replace engine oil filter cartridge....21950
Replace fuel pre-filter cartridge....21952
4.9.10 Every 1000 hours service....21954
Replace fuel main filter cartridge....21954
Change oil in transmission case and transmission oil filter cartridge, clean strainer....21956
Clean transmission case breather....21957
Lubricating....21958
Check of engine air intake piping clamps for looseness....21958
Replace corrosion resistor cartridge....21958
4.9.11 Every 2000 hours service....21959
Change oil in hydraulic tank, replace hydraulic filter element....21959
Replace hydraulic tank breather element....21962
Change axle oil....21963
Replace element in air conditioner recirculation air filter, fresh air filter....21964
Check brake disc wear....21964
Checking function of accumulator....21966
Check alternator....21967
Check engine valve clearance, adjust....21967
Check vibration damper....21967
4.9.12 Every 4000 hours service....21968
Lubricating....21968
Check water pump....21969
Check air conditioner compressor, adjust....21969
Check for loose engine high-pressure piping clamps, hardening of rubber....21970
Checking for missing fuel spray prevention cap, hardening of rubber....21970
Check starting motor....21971
4.9.13 Every 8000 hours service....21971
Replace high-pressure piping clamp....21971
Replace fuel spray prevention cap....21971
4.9.14 Every 12000 hours service....21971
Replace injector assembly....21971
5. Technical Data....21972
5.1 Technical data....21973
5.2 Noise emission levels....21975
5.3 Vibration level....21976
5.4 Limit values for slopes....21978
6. Attachments, Options....21980
6.1 Selecting bucket and tires....21981
6.2 Handling torque converter lock-up....21982
6.2.1 General locations....21983
6.2.2 Method of operation....21985
6.2.3 Warning/limit functions for travel speed....21986
Travel speed warning function....21986
Travel speed limit function....21986
6.3 Handling machines equipped with KOMTRAX....21987
6.3.1 Basic precautions....21988
6.4 Joystick steering system....21989
6.4.1 Components....21989
6.4.2 Structure and function....21992
Operation using joystick lever and operation using steering wheel....21993
Getting in or out....21994
Adjustment of joystick console....21995
6.4.3 Operation method of joystick steering system....21996
6.5 Multi-function lever (with/without auxiliary control lever)....21999
6.5.1 Explanation of components....21999
6.5.2 Operation....22004
Using switch to change between forward and reverse....22004
6.6 3-lever control....22006
6.6.1 Explanation of components....22006
6.7 Hydraulic quick coupler (operation with lever)....22009
6.7.1 Installing the attachment....22009
6.7.2 Removal and installation of the attachment....22012
6.7.3 Precautions for use....22012
6.7.4 Precautions when removing the attachment....22012
6.8 Hydraulic quick coupler (operation with switch)....22013
6.8.1 Removing the attachment....22013
6.8.2 Installing the attachment....22014
6.8.3 Removal and installation of the attachment....22016
6.8.4 Precautions for use....22016
6.8.5 Precautions when removing the attachment....22016
6.9 Central lubrication system....22017
6.9.1 Operating the central lubrication system....22017
6.9.2 Display and control unit....22017
LED-display....22018
Pushbuttons....22018
6.9.3 Changing the lubrication interval times....22019
6.10 Cold area kit....22020
7. Index....22022
7.1 Index....22023
8. Notes....22028
VEBM480104 - Wheel Loader WA470-3 Shop Manual (Serial Number WA470H20051 & up)....22034
Contents....22035
01 General....22042
Up to SN WA470H20668....22044
Dimensions and weights....22044
Specifications....22045
Weight table....22047
List of lubricant and water....22048
From SN WA470H20669 up to SN WA470H20941....22049
Dimensions and weights....22049
Specifications....22050
Weight table....22052
List of lubricant and water....22053
SN WA470H20942 and up....22054
Specifications....22054
Weight table....22055
List of lubricant and water....22056
Outlines of service....22058
General view of controls and gauges....22062
Torque list....22064
10 Structure and function....22066
Power train....22068
Power train system....22069
Torque converter, transmission piping....22071
Transmission hydraulic system diagram....22072
Transmission hydraulic circuit diagram....22073
Torque converter....22074
Transmission....22078
Clutch....22080
Transmission control valve....22088
Transmission solenoid valve....22091
Main relief valve....22093
Torque converter outlet port valve....22094
Priority valve....22095
Directional selector valve....22099
H-L selector valve and range selector valve....22100
Emergency manual spool....22102
Electronic control modulation valve (ECMV)....22103
Pilot oil filter....22106
Accumulator valve....22107
Flow valve....22109
Drive shaft....22112
Axle....22113
Differential....22115
Final drive....22122
Axle mount, center hinge pin....22123
Steering piping....22124
Steering column, orbit roll....22125
Orbit-roll valve....22127
Steering demand valve....22128
Overload relief valve....22129
Steering relief valve....22131
Operation of demand valve....22132
Emergency steering....22142
Brake piping....22152
Brake circuit diagram....22153
Brake valve....22154
Charge valve....22159
Accumulator for system brake....22163
Slack adjuster....22164
Brake pressure regulating valve....22175
Accumulator for PPC valve....22177
Brake accumulator unit....22179
Brake....22180
Parking brake control....22182
Parking brake....22183
Parking brake valve....22184
Hydraulic piping....22186
Work equipment hydraulic system diagram....22187
Work equipment hydraulic circuit diagram....22189
Work equipment lever linkage....22195
Hydraulic tank....22196
Breather....22197
PPC valve....22198
PPC relief valve....22206
Accumulator for PPC valve....22207
Cut-off valve....22208
Main control valve....22210
Relief valve....22218
Safety valve (with suction)....22219
Suction valve....22220
Hydraulic safety system....22230
Work equipment linkage....22234
Bucket....22236
Bucket positioner and boom kick-out....22237
Machine monitor system....22244
Transmission auto-shift control system....22252
Transmission controller....22257
E.C.S.S. (electronic controlled suspension system)....22260
ALS system....22264
Sensors....22270
Engine start circuit....22276
Engine stop circuit....22277
Preheating circuit....22278
Ribbon heater....22283
Electric transmission control....22284
Combination switch....22285
Kick-down, hold switch....22287
Transmission electric circuit diagram....22288
Transmission cut-off switch....22293
Transmission cut-off function....22294
Electric parking brake control....22295
Air-conditioner....22296
Wiring diagrams....22350
20 Testing and adjusting....22386
Standard value table for engine....22387
Standard value table for chassis....22390
Test certificate....22393
Standard value table for electrical parts....22398
Tools for testing, adjusting and troubleshooting....22402
Frm SN WA470H20669 up to SN WA470H20941: MTA11(STC)....22407
Measuring engine speed....22408
Measuring intake air pressure ....22409
Testing and adjusting valves and injectors....22410
Measuring blow-by pressure....22417
Measuring engine oil pressure....22418
Testing the fan belt tension....22419
Measuring stall speed....22421
Up to SN WA470H20668: S6D125-1; SN WA470H20942 and up:SA6D125E-2....22424
Measuring engine speed....22424
Measuring intake air pressure (boost pressure)....22425
Adjusting valve clearance....22426
Mesuring exhaust color....22427
Measuring exhaust gas temperature....22428
Measuring blow-by pressure....22429
Measuring compression pressure....22430
Measuring engine oil pressure....22431
Testing and adjusting fuel injection timing....22432
Method for adjusting engine motor stop cable....22434
Testing and adjusting fan belt tension....22436
Measuring accelerator pedal....22437
Basic adjustment of accelerator pedal....22439
Measuring operating force, travel of speed lever....22441
Measuring stall speed....22442
Measuring torque converter, transmission, parking brake oil pressure....22444
Method of operating emergency manual spool....22446
Measuring clearance between tyre and wheel....22448
Measuring steering oil pressure....22451
Measuring brake performance....22454
Testing brake oil pressure....22455
Measuring brake disc wear....22456
Bleeding air from brake system....22457
Measuring parking brake performance....22458
Method of manual release of parking brake....22459
Testing wear of parking brake disc....22460
Measuring work equipment control lever....22461
Measuring work equipment hydraulic pressure....22463
Measuring PPC valve pressure....22467
Measuring work equipment....22469
Testing and adjusting bucket positioner....22471
Testing and adjusting boom kick-out....22472
Adjusting main monitor (speedometer modul)....22474
Checking for abnormality in fuel level sensor....22475
30 Disassembly and assembly....22694
Method of using manual....22696
Precautions when carrying out operation....22697
Special tool list....22699
Starting motor....22702
Alternator....22703
Engine oil cooler....22704
Fuel injection pump....22705
Water pump....22709
Turbocharger....22710
Nozzle holder....22711
Thermostat....22712
Cylinder head....22713
Radiator....22719
Engine....22722
Torque converter charging pump....22729
Torque converter, transmission....22730
Torque converter....22739
Tranmission....22744
Transmission clutch pack....22755
Parking brake....22776
Transmission control valve....22781
Transmission accumulator valve....22799
Drive shaft....22802
Front axle....22806
Rear axle....22809
Front differential....22814
Rear differential....22819
Differential....22824
Final drive....22835
Center hinge pin....22842
Steering, orbit roll....22856
Steering valve....22858
Steering, switch pump....22873
Steering cylinder....22877
Brake valve....22879
Right brake valve (tandem)....22881
Left brake valve (single)....22883
Slack adjuster....22885
Brake....22889
Parking brake disc....22903
Hydraulic tank....22906
Work equipment, PPC pump....22909
PPC valve....22916
Main control valve....22918
Bucket cylinder....22926
Boom cylinder....22928
Hydraulic cylinder....22930
Work equipment....22936
Counterweight....22941
Fuel tank....22942
Cab....22944
Main monitor....22946
Maintenance monitor....22948
Air conditioner unit....22949
Air conditioner condenser....22955
Dry receiver....22957
Air conditioner compressor....22958
Tyres....22960
40 Maintenance standard....22968
Engine mount, transmission mount....22969
Torque converter....22970
Transmission....22971
Transmission control valve....22981
Drive shaft....22985
Diffential....22987
Final drive....22989
Axle mount....22990
Steerig column, orbit roll....22991
Steering valve....22993
Steering cylinder mount....22994
Slack adjuster....22995
Brake valve....22996
Brake....22999
Parking brake....23001
Torque converter, transmission pump....23002
Steering, switch pump....23003
Hydraulic, PPC pump....23004
PPC valve....23005
Cut-off valve....23006
Main control valve....23007
Boom cylinder....23011
Bucket cylinder....23012
Center hinge pin....23013
Work equipment linkage....23015
Bucket....23017
Bucket positioner and boom kick-out....23018
Diagrams....23020
Diagrams_A3....23020
Diagrams_A2....23036
Komatsu Wheel Loader WA470 Repair Service Manuals
