WHEEL LOADER
WA 470 -7
SERIAL NUMBERS H52051 and up 10001 and up
WHEELLOADER
100Indexandforeword
Index (ALL-0310-001-A-00-A)
00Indexandforeword.......................................................................................................................00-1
Index.........................................................................................................................................00-2
Foreword,safetyandgeneralinformation...................................................................................00-18
Importantsafetynotice.......................................................................................................00-18
Howtoreadtheshopmanual..............................................................................................00-25
Explanationoftermsformaintenancestandard....................................................................00-27
Handlingequipmentoffuelsystemdevices..........................................................................00-29
Handlingofintakesystemparts...........................................................................................00-30
Handlingofhydraulicequipment..........................................................................................00-31
Methodofdisconnectingandconnectingofpush-pulltypecoupler.........................................00-33
Handlingofelectricalequipment..........................................................................................00-36
Howtoreadelectricwirecode.............................................................................................00-44
Precautionswhenperformingoperation...............................................................................00-47
PracticaluseofKOMTRAX.................................................................................................00-51
Standardtighteningtorquetable..........................................................................................00-52
Listofabbreviation.............................................................................................................00-56
Conversiontable................................................................................................................00-61
01Specification.................................................................................................................................01-1
Tableofcontents........................................................................................................................01-2 Specifications.............................................................................................................................01-3
Specificationdrawing...........................................................................................................01-3 Specifications......................................................................................................................01-5
Weighttable......................................................................................................................01-11
Tableoffuel,coolant,andlubricants....................................................................................01-13
10Structureandfunction...................................................................................................................10-1
Tableofcontents........................................................................................................................10-2
Engineandcoolingsystem..........................................................................................................10-4
EGRsystempipingdrawing................................................................................................10-12
EGRsystemcircuitdiagram................................................................................................10-14
EGRvalve.........................................................................................................................10-15
EGRcooler........................................................................................................................10-17
KCCVlayoutdrawing.........................................................................................................10-19
KCCVventilator.................................................................................................................10-21
KDPF................................................................................................................................10-23
Coolingsystem..................................................................................................................10-27
Coolingfanpump...............................................................................................................10-30
Coolingfanmotor...............................................................................................................10-39
Powertrain...............................................................................................................................10-46
Powertrainsystem.............................................................................................................10-46
Driveshaft.........................................................................................................................10-49
Powertrainpipingdrawing..................................................................................................10-50 Transmissioncontrol..........................................................................................................10-51
Torqueconverter................................................................................................................10-54 Transmission.....................................................................................................................10-59
Transmissioncontrolvalve..................................................................................................10-78
ForwardandreverseclutchECMVand1stand2ndclutchECMV..........................................10-81 3rd,4thclutchECMV..........................................................................................................10-88
LockupclutchECMV..........................................................................................................10-95
Mainreliefandtorqueconverterreliefvalve..........................................................................10-99
Axle................................................................................................................................10-101
Differential.......................................................................................................................10-103 Finaldrive.......................................................................................................................10-113
Steeringsystem......................................................................................................................10-115
Layoutofsteeringparts....................................................................................................10-115
Steeringcolumn...............................................................................................................10-116
Standardvaluetableformachine..........................................................................................20-5
Standardvaluetableforelectricalsystem.............................................................................20-18
30Testingandadjusting....................................................................................................................30-1
Tableofcontents........................................................................................................................30-2
Generalinformationontestingandadjusting.................................................................................30-4
Toolsfortestingandadjusting...............................................................................................30-4
Sketchoftoolsfortestingandadjusting.................................................................................30-8
Engineandcoolingsystem........................................................................................................30-10
Testingenginespeed.........................................................................................................30-10
Testingboostpressure.......................................................................................................30-12
Testingexhaustgascolor...................................................................................................30-14
Testingandadjustingvalveclearance..................................................................................30-16
Testingcompressionpressure.............................................................................................30-18
Testingblowbypressure.....................................................................................................30-22
Testingengineoilpressure.................................................................................................30-24
TestingEGRvalveandKVGToilpressures..........................................................................30-25
Testingfuelpressure..........................................................................................................30-26
Testingfuelreturnrateandleakage.....................................................................................30-27
Bleedingairfromfuelsystem..............................................................................................30-31
Testingfuelcircuitforleakage.............................................................................................30-33
Handlingcylindercutoutmodeoperation..............................................................................30-34
Handlingnoinjectioncrankingoperation..............................................................................30-35
TestingofKDPFandmufflerstackforloosenessanddamage...............................................30-36
Testingofinstalledconditionofcylinderheadandmanifolds..................................................30-37
Testingenginepipingfordamageandlooseness..................................................................30-38
Testingandadjustingairconditionercompressorbelttension................................................30-39
Testingandadjustingalternatorbelttension.........................................................................30-41
Proceduresforcleaningfueldoser.......................................................................................30-43
Writingcompensationvaluesatreplacementofinjectorandenginecontroller.........................30-46
Powertrain...............................................................................................................................30-50
Adjustingtransmissionoutputspeedsensor.........................................................................30-50
Adjustingtransmissioninputspeedsensor...........................................................................30-51
Flushingprocedurefortorqueconverterandtransmissionhydrauliccircuit..............................30-52
Retrievalofdisabledmachineduetotransmissionvalvefailure..............................................30-54
Testingoilleakagefromaxlefinaldrive................................................................................30-56
Testingdriveshaftforlooseness,backlash,anddamage.......................................................30-57
Testingandadjustingpowertrainoilpressure.......................................................................30-58
Steeringsystem........................................................................................................................30-73
Testingdirectionallever......................................................................................................30-73
Testingsteeringwheel........................................................................................................30-74
Testingworkequipmentcontrollever...................................................................................30-76
Testingandadjustingsteeringcircuitoilpressure..................................................................30-78
Bleedingairfromsteeringcylindercircuit..............................................................................30-81
Testingandadjustingsteeringstoppervalve.........................................................................30-82
Brakesystem...........................................................................................................................30-83
Testingbrakepedal............................................................................................................30-83
Testingandadjustingbrakepedallinkage............................................................................30-84
Testingbrakingperformance...............................................................................................30-85
Testingandadjustingofaccumulatorchargepressure...........................................................30-86
Testingofbrakeaccumulatornitrogengaspressureandprocedureforchargingbrake accumulatorwithnitrogengas................................................................................30-88
Testingwheelbrakeoilpressure..........................................................................................30-92
Testingloweringofwheelbrakepressure.............................................................................30-94
Testingwearofwheelbrakedisc.........................................................................................30-96
Bleedingairfromwheelbrakecircuit....................................................................................30-97
Releasingremainingpressureinbrakeaccumulatorcircuit....................................................30-99
Testingparkingbrakeperformance....................................................................................30-100
Testingparkingbrakeoilpressure.....................................................................................30-101
Testingwearofparkingbrakedisc.....................................................................................30-102
Methodofreleasingparkingbrakemanually.......................................................................30-103
Hydraulicsystem....................................................................................................................30-105
Testingfanspeed.............................................................................................................30-105
Testingfanpumpcircuitoilpressure..................................................................................30-106
Bleedingairfromhydraulicfancircuit.................................................................................30-108
TestingandadjustingworkequipmentEPCoilpressure......................................................30-110
Testingandadjustingworkequipmentoilpressure..............................................................30-113
Bleedingairfromworkequipmentcircuit............................................................................30-117
Releasingremainingpressurefromworkequipmentcircuit..................................................30-118
TestingofECSSaccumulatornitrogengaspressureandprocedureforchargingaccumulator withnitrogengas................................................................................................30-119
Workequipment.....................................................................................................................30-123
Testingandadjustingbucketpositiondetectionlever...........................................................30-123
Testingandadjustingboompositiondetectionlever............................................................30-124
Electricalsystem....................................................................................................................30-125
Adjustingreplaced,reassembledoraddedsensor,controller,etc.withmachine monitor..............................................................................................................30-125
Specialfunctionsofmachinemonitor.................................................................................30-127
Adjustingrearviewcameraangle.......................................................................................30-216
Fuselocationtable...........................................................................................................40-104
PrecautionsforKDPF(KCSFandKDOC)CleaningandReplacement.................................40-107
Precautionsontroubleshootingofmachinemonitor............................................................40-110
ProcessingprocedureofharnesscheckerfortroubleshootingofmachinemonitorLCD unit....................................................................................................................40-112
Fabricationofdummytemperaturesensor(forKDOCandKDPFtemperature sensors).............................................................................................................40-117
Fabricationofshort-circuitconnector(forCA1883andCA3135)...........................................40-118
Failurecodestable...........................................................................................................40-119
Troubleshootingbyfailurecode(Displayofcode)......................................................................40-133
Failurecode[1500L0]DoubleEngagementofT/MClutches................................................40-133
Failurecode[15SAL1]ReleaseTroubleofECMV(Forward)................................................40-134
Failurecode[15SALH]MalfunctionofECMV(Forward).......................................................40-136
Failurecode[15SBL1]ReleaseTroubleofECMV(Reverse)................................................40-138
Failurecode[15SBLH]MalfunctionofECMV(Reverse)......................................................40-140
Failurecode[15SEL1]ReleaseTroubleofECMV(1st)........................................................40-142
Failurecode[15SELH]MalfunctionofECMV(1st)..............................................................40-144
Failurecode[15SFL1]ReleaseTroubleofECMV(2nd).......................................................40-146
Failurecode[15SFLH]MalfunctionofECMV(2nd).............................................................40-148
Failurecode[15SGL1]ReleaseTroubleofECMV(3rd).......................................................40-150
Failurecode[15SGLH]MalfunctionofECMV(3rd)..............................................................40-152
Failurecode[15SHL1]ReleaseTroubleofECMV(4th).......................................................40-154
Failurecode[15SHLH]MalfunctionofECMV(4th)..............................................................40-156
Failurecode[2F00MA]FailureofParkingBrakeCircuit.......................................................40-158 Failurecode[2G42ZG]AccumulatorOilPressureLow(Front).............................................40-162
Failurecode[2G43ZG]AccumulatorOilPressureLow(Rear)..............................................40-164
Failurecode[879AKA]A/CInnerSensorOpenCircuit........................................................40-166 Failurecode[879AKB]A/CInnerSensorShortCircuit.........................................................40-167 Failurecode[879BKA]A/COuterSensorOpenCircuit........................................................40-168 Failurecode[879BKB]A/COuterSensorShortCircuit........................................................40-169
Failurecode[879CKA]VentilatingSensorOpenCircuit.......................................................40-170
Failurecode[879CKB]VentilatingSensorShortCircuit.......................................................40-171 Failurecode[879DKZ]SunlightSensorOpenorShortCircuit..............................................40-172 Failurecode[879EMC]VentilationDamperAbnormality......................................................40-173 Failurecode[879FMC]AirMixDamperAbnormality...........................................................40-174 Failurecode[989A00]EngineOverrunPreventionActivated...............................................40-175 Failurecode[989L00]EngineControllerLockCaution1......................................................40-176 Failurecode[989M00]EngineControllerLockCaution2.....................................................40-177 Failurecode[989N00]EngineControllerLockCaution3.....................................................40-178 Failurecode[A1U0N3]HCDesorbRequest1....................................................................40-179 Failurecode[A1U0N4]HCDesorbRequest2....................................................................40-181 Failurecode[AA10NX]AirCleanerClogging......................................................................40-183 Failurecode[B@BAZG]EngOilPressLow.......................................................................40-185 Failurecode[B@BAZK]EngOilLevelLow........................................................................40-186 Failurecode[B@BCNS]EngWaterOverheat....................................................................40-188 Failurecode[B@BCZK]EngWaterLevelLow...................................................................40-189 Failurecode[B@CENS]T/COilTemp.Overheat................................................................40-191 Failurecode[B@HANS]HYDOilTemp.Overheat..............................................................40-192 Failurecode[CA115]EngNeandBkupSpeedSensError..................................................40-193 Failurecode[CA122]ChgAirPressSensorHighError.......................................................40-194 Failurecode[CA123]ChgAirPressSensorLowError........................................................40-196 Failurecode[CA131]ThrottleSensorHighError.................................................................40-198 Failurecode[CA132]ThrottleSensorLowError.................................................................40-200 Failurecode[CA135]EngOilPressSensorHighError........................................................40-202 Failurecode[CA141]EngOilPressSensorLowError........................................................40-204 Failurecode[CA144]CoolantTempSensHighError..........................................................40-206 Failurecode[CA145]CoolantTempSensLowError...........................................................40-208 Failurecode[CA153]ChgAirTempSensorHighError........................................................40-210 Failurecode[CA154]ChgAirTempSensorLowError.........................................................40-212 Failurecode[CA187]Sensor2SupplyVoltLowError.........................................................40-214 Failurecode[CA221]AmbientPressSensorHighError......................................................40-216 Failurecode[CA222]AmbientPressSensorLowError.......................................................40-218 Failurecode[CA227]Sensor2SupplyVoltHighError.........................................................40-220 Failurecode[CA234]EngOverspeed................................................................................40-221 Failurecode[CA238]NeSpeedSensorSupplyVoltError...................................................40-222 Failurecode[CA239]NeSpeedSensSupplyVoltHighError...............................................40-223 Failurecode[CA271]IMV/PCV1ShortError......................................................................40-224 Failurecode[CA272]IMV/PCV1OpenError......................................................................40-225 Failurecode[CA273]PCV2ShortError.............................................................................40-226 Failurecode[CA274]PCV2OpenError.............................................................................40-227 Failurecode[CA322]Inj#1(L#1)Open/ShortError.............................................................40-228 Failurecode[CA323]Inj#5(L#5)Open/ShortError.............................................................40-230 Failurecode[CA324]Inj#3(L#3)Open/ShortError.............................................................40-232 Failurecode[CA325]Inj#6(L#6)Open/ShortError.............................................................40-234 Failurecode[CA331]Inj#2(L#2)Open/ShortError.............................................................40-236 Failurecode[CA332]Inj#4(L#4)Open/ShortError.............................................................40-238 Failurecode[CA343]ECMCriticalInternalFailure..............................................................40-240 Failurecode[CA351]InjectorsDriveCircuitError...............................................................40-241 Failurecode[CA352]Sensor1SupplyVoltLowError.........................................................40-242
Failurecode[CA356]MassAirFlowSensorHighError.......................................................40-244
Failurecode[CA357]MassAirFlowSensorLowError........................................................40-246
Failurecode[CA386]Sensor1SupplyVoltHighError.........................................................40-248
Failurecode[CA431]IdleValidationSwError.....................................................................40-249
Failurecode[CA432]IdleValidationProcessError.............................................................40-252
Failurecode[CA441]BatteryVoltageLowError.................................................................40-255
Failurecode[CA442]BatteryVoltageHighError.................................................................40-257
Failurecode[CA449]RailPressVeryHighError.................................................................40-258
Failurecode[CA451]RailPressSensorHighError.............................................................40-259
Failurecode[CA452]RailPressSensorLowError.............................................................40-261
Failurecode[CA515]RailPressSensSupVoltHighError..................................................40-263
Failurecode[CA516]RailPressSensSupVoltLowError...................................................40-265
Failurecode[CA553]RailPressHighError........................................................................40-267
Failurecode[CA555]CrankcasePressHighError1...........................................................40-268
Failurecode[CA556]CrankcasePressHighError2...........................................................40-269
Failurecode[CA559]RailPressLowError.........................................................................40-270 Failurecode[CA595]TurboSpeedHighError2.................................................................40-274 Failurecode[CA687]TurboSpeedLowError.....................................................................40-275 Failurecode[CA689]EngNeSpeedSensorError..............................................................40-277 Failurecode[CA691]IntakeAirTempSensHighError........................................................40-279
Failurecode[CA692]IntakeAirTempSensLowError.........................................................40-281
Failurecode[CA697]ECMInternalTempSensorHighError................................................40-283
Failurecode[CA698]ECMIntTempSensorLowError........................................................40-284 Failurecode[CA731]EngBkupSpeedSensPhaseError...................................................40-285
Failurecode[CA778]EngBkupSpeedSensorError...........................................................40-286 Failurecode[CA1117]PersistentDataLostError................................................................40-288 Failurecode[CA1664]KDOCMalfunction..........................................................................40-289 Failurecode[CA1691]RegenerationIneffective.................................................................40-292 Failurecode[CA1695]Sensor5SupplyVoltHighError.......................................................40-295 Failurecode[CA1696]Sensor5SupplyVoltLowError.......................................................40-296 Failurecode[CA1843]CrankcasePressSensHighError....................................................40-298 Failurecode[CA1844]CrankcasePressSensLowError....................................................40-300 Failurecode[CA1879]KDPFDeltaPSensorHighError.....................................................40-302 Failurecode[CA1881]KDPFDeltaPSensorLowError......................................................40-304 Failurecode[CA1883]KDPFDeltaPSensInRangeError..................................................40-306 Failurecode[CA1921]KDPFSootLoadHighError1..........................................................40-309 Failurecode[CA1922]KDPFSootLoadHighError2..........................................................40-312 Failurecode[CA1923]DosingFuelValve1HighError........................................................40-317 Failurecode[CA1924]DosingFuelValve1LowError.........................................................40-319 Failurecode[CA1925]DosingFuelValve1InRangeError.................................................40-322 Failurecode[CA1927]DosingFuelPressSensHighError..................................................40-324 Failurecode[CA1928]DosingFuelPressSensLowError...................................................40-326 Failurecode[CA1942]CrankcasePressSensInRangeError.............................................40-328 Failurecode[CA1963]DosingFuelValve1ServoError......................................................40-329 Failurecode[CA1977]FuelDoserOpen/ShortError...........................................................40-331 Failurecode[CA1993]KDPFDeltaPressureLowError......................................................40-333 Failurecode[CA2185]ThrotSensorSupVoltHighError.....................................................40-335 Failurecode[CA2186]ThrotSensorSupVoltLowError......................................................40-337 Failurecode[CA2249]RailPressVeryLowError...............................................................40-339 Failurecode[CA2265]FuelFeedPumpOpenError............................................................40-340 Failurecode[CA2266]FuelFeedPumpShortError............................................................40-342 Failurecode[CA2271]EGRValvePosSensHighError......................................................40-344 Failurecode[CA2272]EGRValvePosSensLowError.......................................................40-346 Failurecode[CA2349]EGRValveSolenoidOpenError......................................................40-348 Failurecode[CA2353]EGRValveSolenoidShortError......................................................40-350 Failurecode[CA2357]EGRValveServoError...................................................................40-352 Failurecode[CA2381]KVGTPosSensHighError.............................................................40-353 Failurecode[CA2382]KVGTPosSensLowError..............................................................40-355 Failurecode[CA2383]KVGTSolenoidOpenError.............................................................40-357
Failurecode[CA2386]KVGTSolenoidShortError.............................................................40-359 Failurecode[CA2387]KVGTServoError..........................................................................40-361 Failurecode[CA2555]GridHtrRelayVoltLowError...........................................................40-362 Failurecode[CA2556]GridHtrRelayVoltHighError..........................................................40-364 Failurecode[CA2637]KDOCFacePlugging.....................................................................40-366 Failurecode[CA2639]ManualStationaryRegenerationRequest.........................................40-368 Failurecode[CA2732]DosingFuelValve2HighError........................................................40-371 Failurecode[CA2733]DosingFuelValve2LowError.........................................................40-373 Failurecode[CA2741]DosingFuelValveSwapError.........................................................40-375 Failurecode[CA2765]InjTrimDataError..........................................................................40-377 Failurecode[CA2878]DosingFuelValve2ServoError......................................................40-378 Failurecode[CA2881]DosingFuelPressureLowError1....................................................40-381 Failurecode[CA3133]KDPFOutletPressSensHighError.................................................40-386 Failurecode[CA3134]KDPFOutletPressSensLowError..................................................40-388 Failurecode[CA3135]KDPFOutletPressSensInRangeError..........................................40-390 Failurecode[CA3167]FuelDoserDegradation..................................................................40-393 Failurecode[CA3251]KDOCInletTempHighError............................................................40-396 Failurecode[CA3253]KDOCTempError-NonRegeneration.............................................40-399 Failurecode[CA3254]KDOCOutletTempHighError1......................................................40-402 Failurecode[CA3255]KDPFTempError-NonRegeneration..............................................40-405 Failurecode[CA3256]KDPFOutletTempHighError1.......................................................40-409 Failurecode[CA3311]KDOCOutletTempHighError2.......................................................40-412 Failurecode[CA3312]KDPFOutletTempHighError2.......................................................40-415 Failurecode[CA3313]KDOCInletTempSensorLowError.................................................40-418 Failurecode[CA3314]KDOCInletTempSensHighError...................................................40-421 Failurecode[CA3315]KDOCInletTempSensInRangeError.............................................40-425 Failurecode[CA3316]KDOCOutletTempSensLowError.................................................40-430 Failurecode[CA3317]KDOCOutletTempSensHighError.................................................40-433 Failurecode[CA3318]KDOCOutletTempSensInRangeError..........................................40-437 Failurecode[CA3319]KDPFOutletTempSensHighError.................................................40-442 Failurecode[CA3321]KDPFOutletTempSensLowError..................................................40-446 Failurecode[CA3322]KDPFOutletTempSensInRangeError...........................................40-449 Failurecode[CA3419]MassAirFlowSensorSupVoltHighError........................................40-454 Failurecode[CA3421]MassAirFlowSensorSupVoltLowError.........................................40-456 Failurecode[D150KA]DisconnectionofEmerg.SteeringRelay..........................................40-458 Failurecode[D150KB]GroundFaultofEmerg.SteeringRelay............................................40-460 Failurecode[D150KY]HotShortofEmergencySteeringRelay...........................................40-462 Failurecode[D160KA]DisconnectionofBackupLampRelayOutput...................................40-464 Failurecode[D160KB]GroundFaultofBackupLampRelayOutput.....................................40-466 Failurecode[D160KY]HotShortofBackupLampRelayOutput..........................................40-468 Failurecode[D191KA]DisconnectionofNeutralOutputRelay.............................................40-470 Failurecode[D191KB]GroundFaultofNeutralOutputRelay..............................................40-472 Failurecode[D191KY]HotShortofNeutralOutputRelay....................................................40-474 Failurecode[D192KA]DisconnectionofECSSSolenoid.....................................................40-476 Failurecode[D192KB]GroundFaultofECSSSolenoid......................................................40-478 Failurecode[D192KY]HotShortofECSSSolenoid...........................................................40-479 Failurecode[D19JKZ]PersonalCodeRelayAbnormality....................................................40-480 Failurecode[D1E6KA]DisconnectionofParkingBrakeRelay.............................................40-482 Failurecode[D1E6KB]GroundFaultofParkingBrakeRelay...............................................40-484 Failurecode[D1E6KY]HotShortofParkingBrakeRelay....................................................40-486 Failurecode[D5ZHKA]FailureofKeySWCSignal............................................................40-488 Failurecode[D5ZHKB]KeySWCSignalShortCircuit........................................................40-490 Failurecode[D5ZHKZ]FailureofKeySWCSignal............................................................40-492 Failurecode[D5ZHL6]DisconnectionofKeySWC............................................................40-494 Failurecode[D811MC]KOMTRAXError............................................................................40-496 Failurecode[D862KA]GPSAntennaOpenCircuit.............................................................40-497 Failurecode[D8ALKA]OperatingLampOpenCircuit(KOMTRAX)......................................40-498 Failurecode[D8ALKB]OperatingLampShortCircuit(KOMTRAX)......................................40-500 Failurecode[D8AQK4]CAN2Discon(KOMTRAX)2..........................................................40-502
Failurecode[D8AQKR]CAN2Discon(KOMTRAX)............................................................40-503 Failurecode[DAF0KT]AbnormalityofNon-volatileMemory(MON).....................................40-505 Failurecode[DAF0MB]MonitorROMAbnormality..............................................................40-506 Failurecode[DAF0MC]MonitorError................................................................................40-507 Failurecode[DAF3KK]ControllerPowerSourceLow(MON)...............................................40-508 Failurecode[DAF8KB]CameraPowerSupplyShortCircuit................................................40-510 Failurecode[DAFDKB]Monitor12VPowerOutputShortCircuit..........................................40-511 Failurecode[DAFGMC]GPSModuleError........................................................................40-513 Failurecode[DAFLKA]OperatingLampOpenCircuit(MON)...............................................40-514 Failurecode[DAFLKB]OperatingLampShortCircuit(MON)...............................................40-516 Failurecode[DAFQKR]CAN2Discon(Monitor).................................................................40-518 Failurecode[DAQ0KK]ControllerPowerSourceLow(T/M)................................................40-519 Failurecode[DAQ0KT]AbnormalityofNon-volatileMemory(T/M).......................................40-522 Failurecode[DAQ0MC]T/MConError..............................................................................40-523 Failurecode[DAQ1KA]DisconnectionofKeySWACC(T/M)..............................................40-524 Failurecode[DAQ2KK]SolenoidPowerSourceLow(T/M).................................................40-526 Failurecode[DAQ4KB]GroundFaultofSol.Self-HoldingRelay..........................................40-529 Failurecode[DAQ9KQ]InconsistencyofModelSelection(T/M)..........................................40-531 Failurecode[DAQLKA]OperatingLampOpenCircuit(T/M)................................................40-532 Failurecode[DAQLKB]OperatingLampShortCircuit(T/M)................................................40-534 Failurecode[DAQQKR]CAN2Discon(TransmissionCon).................................................40-536 Failurecode[DAQRKR]CAN1Discon(TransmissionCon).................................................40-537 Failurecode[DAQRMA]InconsistencyofOptionSelection(T/M).........................................40-538 Failurecode[DAZ9KQ]A/CModelSelectionAbnormality....................................................40-539 Failurecode[DAZQKR]CAN2Discon(AirconECU)...........................................................40-540 Failurecode[DB2QKR]CAN2Discon(EngineCon)...........................................................40-541 Failurecode[DB2RKR]CAN1Discon(EngineCon)...........................................................40-546 Failurecode[DB90KK]DropinBBCControllerMainPowerSource.....................................40-551 Failurecode[DB90KT]AbnormalityofNon-volatileMemory(BBC)......................................40-553 Failurecode[DB90MC]BBCError.....................................................................................40-554 Failurecode[DB91KA]DisconnectionofKeySWACC(BBC).............................................40-555 Failurecode[DB92KK]SolenoidPowerSourceLow(BBC).................................................40-557 Failurecode[DB95KX]Failureof5VPowerSource1.........................................................40-559 Failurecode[DB96KX]Failureof5VPowerSource2.........................................................40-561 Failurecode[DB99KQ]InconsistencyofModelSelection(BBC)..........................................40-563 Failurecode[DB9LKA]OperatingLampOpenCircuit(BBC)................................................40-564 Failurecode[DB9LKB]OperatingLampShortCircuit(BBC)................................................40-566 Failurecode[DB9QKR]CAN2Discon(BucketBoomCon)..................................................40-568 Failurecode[DB9RKR]CAN1Discon(BucketBoomCon)..................................................40-569 Failurecode[DB9RMA]InconsistencyofOptionSelection(BBC).........................................40-570 Failurecode[DBE5KX]Failureof5VPowerSource............................................................40-571 Failurecode[DBE6KX]Failureof24VPowerSource.........................................................40-573 Failurecode[DD1ALD]GroundFaultofRemotePositionerSetSW.....................................40-575 Failurecode[DDAAL6]DisconofEngineShutdownSecondarySwitch................................40-577 Failurecode[DDB6L4]NeutralSignalMalfunction..............................................................40-579 Failurecode[DDD1LD]FailureofBucketPositionerSetSwitch...........................................40-582 Failurecode[DDK3KA]FNRSWInputSignalDisconnection...............................................40-584 Failurecode[DDK3KB]FNRSWInputSignalShortCircuit..................................................40-587 Failurecode[DDK6KA]FNRLeverInputSignalDisconnection............................................40-589 Failurecode[DDK6KB]FNRLeverInputSignalShortCircuit...............................................40-592 Failurecode[DDNRKY]HotShortofWorkEquipmentLockSW..........................................40-594 Failurecode[DDT0L4]FailureofShiftModeSelectSW......................................................40-596 Failurecode[DDT4LD]GroundFaultofT/MCutOffSetSWSignal......................................40-598 Failurecode[DDT9LD]GroundFaultofT/MCutOffSWSignal...........................................40-600 Failurecode[DDW9LD]GroundFaultofKickdownSwitch...................................................40-602 Failurecode[DDWLLD]GroundFaultofT/MShiftHoldSW................................................40-604 Failurecode[DF10KA]DisconnectionofShiftLeverInput...................................................40-606 Failurecode[DF10KB]GroundFaultofShiftLeverInput.....................................................40-608 Failurecode[DGF1KA]DisconnectionofT/MOilTemp.Sensor...........................................40-611
Failurecode[DGF1KB]GroundFaultofT/MOilTemp.Sensor............................................40-613 Failurecode[DGH2KX]OutofRangeofHYDOilTemp.Sensor..........................................40-615 Failurecode[DGR2KB]GroundFaultofBrakeOilTemp.Sensor.........................................40-617 Failurecode[DGR2KZ]FailureofBrakeOilTemp.Sensor..................................................40-618 Failurecode[DGT1KA]DisconnectionofT/COilTemp.Sensor...........................................40-620 Failurecode[DGT1KB]GroundFaultofT/COilTemp.Sensor.............................................40-623 Failurecode[DH21KA]FailureofLoaderPumpPress.Sensor............................................40-625 Failurecode[DH21KB]LoaderPumpPress.SensorShortCircuit........................................40-627 Failurecode[DHA4KA]FailureofAirCleanerSensorCircuit...............................................40-629 Failurecode[DHPCKX]OutofRangeofBoomBottomPress.Sensor..................................40-631 Failurecode[DHPDKX]OutofRangeofBoomHeadPress.Sensor....................................40-633 Failurecode[DHT1KX]OutofRangeofT/MCutOffPress.Sensor......................................40-635 Failurecode[DHT5KX]OutofRangeofT/CInputPressureSensor.....................................40-637 Failurecode[DHT7KX]OutofRangeofT/COutputPressureSensor..................................40-639 Failurecode[DHT8KA]FailureofSteeringPumpPress.Sensor..........................................40-641 Failurecode[DHT8KB]SteeringPumpPress.SensorShortCircuit......................................40-643 Failurecode[DHT8ZG]SteeringOilPressureLow..............................................................40-645 Failurecode[DHUDKA]FailureofEmrg.SteeringPress.Sensor.........................................40-646 Failurecode[DHUDKB]Emrg.SteeringPress.S.ShortCircuit............................................40-648 Failurecode[DJF1KA]DisconnectionofFuelLevelSensor.................................................40-650 Failurecode[DK55KA]FailureofFNRLeverPotentio.........................................................40-652 Failurecode[DK55KY]HotShortofFNRLeverPotentioCircuit...........................................40-655 Failurecode[DK55L5]FailureofFNRLeverPotentio..........................................................40-657 Failurecode[DK59KA]FailureofBoomLeverPotentio(Main).............................................40-658 Failurecode[DK59KY]HotShortofBoomLeverPotentio(Main).........................................40-661 Failurecode[DK59L8]BoomLeverPotentio(Main&Sub)Disagree....................................40-664 Failurecode[DK5AKA]FailureofBoomLeverPotentio(Sub)..............................................40-668 Failurecode[DK5AKY]HotShortofBoomLeverPotentio(Sub)..........................................40-671 Failurecode[DK5BKA]FailureofBucketLeverPotentio(Main)...........................................40-674 Failurecode[DK5BKY]HotShortofBucketLeverPotentio(Main).......................................40-677 Failurecode[DK5BL8]BucketLeverPotentio(Main&Sub)Disagree....................................40-680 Failurecode[DK5CKA]FailureofBucketLeverPotentio(Sub)............................................40-684 Failurecode[DK5CKY]HotShortofBucketLeverPotentio(Sub)........................................40-687 Failurecode[DK5DKA]Failureof3rdLeverPotentio(Main)................................................40-690 Failurecode[DK5DKY]HotShortof3rdLeverPotentio(Main)............................................40-693 Failurecode[DK5DL8]3rdLeverPotentio(Main&Sub)Disagree........................................40-695 Failurecode[DK5EKA]Failureof3rdLeverPotentio(Sub)..................................................40-698 Failurecode[DK5EKY]HotShortof3rdLeverPotentio(Sub)..............................................40-701 Failurecode[DKA0KA]FailureofBoomAngleSensor........................................................40-703 Failurecode[DKA0KY]HotShortofBoomAngleSensorCircuit..........................................40-705 Failurecode[DKA0L0]BoomAngleSensorDislocation......................................................40-707 Failurecode[DKA1KA]FailureofBucketAngleSensor.......................................................40-709 Failurecode[DKA1KY]HotShortofBucketAngleSensorCircuit.........................................40-711 Failurecode[DLF1KA]DisconnectionofT/MInputSpeedSensor........................................40-713 Failurecode[DLF1LC]FailureofT/MInputSpeedSensor...................................................40-715 Failurecode[DLM3KA]DisconnectionofRadiatorFanSpeedSensor..................................40-717 Failurecode[DLM3LC]FailureofRadiatorFanSpeedSensor.............................................40-719
Failurecode[DLT3KA]DisconnectionofOutputSpeedSens.(Main)....................................40-721 Failurecode[DLT3LC]FailureofOutputSpeedSensor(Main).............................................40-723 Failurecode[DPQ1KR]LINDiscon(SwitchPanel).............................................................40-725 Failurecode[DPQ2KR]LINDiscon(LEDUnit)...................................................................40-728 Failurecode[DPQ3KR]LINDiscon(RearViewMonitor).....................................................40-731 Failurecode[DSJ0KR]CAN2Discon(MeterUnit)..............................................................40-734 Failurecode[DT20KB]GroundFaultofT/MCutOffIndicator..............................................40-736 Failurecode[DT22KB]GroundFaultofWorkEquip.LockIndic...........................................40-738 Failurecode[DV00KB]GroundFaultofBuzzerOutput........................................................40-740 Failurecode[DW4PKA]DisconnectionofBoomEPCSolenoid(Raise)................................40-742 Failurecode[DW4PKB]GroundFaultofBoomEPCSolenoid(Raise)..................................40-744 Failurecode[DW4PKY]HotShortofBoomEPCSolenoid(Raise).......................................40-746
Failurecode[DW4QKA]DisconnectionofBoomEPCSolenoid(Lower)...............................40-748 Failurecode[DW4QKB]GroundFaultofBoomEPCSolenoid(Lower).................................40-750 Failurecode[DW4QKY]HotShortofBoomEPCSolenoid(Lower)......................................40-752 Failurecode[DW4RKA]DisconnectionofBucketEPCSol.(Tilt)..........................................40-754 Failurecode[DW4RKB]GroundFaultofBucketEPCSolenoid(Tilt)....................................40-756 Failurecode[DW4RKY]HotShortofBucketEPCSolenoid(Tilt)..........................................40-758 Failurecode[DW4SKA]DisconnectionofBucketEPCSol.(Dump).....................................40-760 Failurecode[DW4SKB]GroundFaultofBucketEPCSolenoid(Dump)................................40-762 Failurecode[DW4SKY]HotShortofBucketEPCSolenoid(Dump).....................................40-764 Failurecode[DW7BKA]DisconnectionofFanReverseSolenoid.........................................40-766 Failurecode[DW7BKB]GroundFaultofRadiatorFanRev.Sol...........................................40-768 Failurecode[DW7BKY]HotShortofRadiatorFanRev.Sol.................................................40-770 Failurecode[DWM1KA]DisconnectionofNeutralLockSolenoid.........................................40-771 Failurecode[DWM1KB]GroundFaultofNeutralLockSolenoid...........................................40-773 Failurecode[DWM1KY]HotShortofNeutralLockSolenoid................................................40-775 Failurecode[DWN6KA]DisconnectionofDetentSolenoid(Boom)......................................40-777 Failurecode[DWN6KB]GroundFaultofDetentSolenoid(Boom)........................................40-779 Failurecode[DWN6KY]HotShortofDetentSolenoid(Boom).............................................40-781 Failurecode[DWN8KA]DisconnectionofDetentSolenoid(Bucket).....................................40-783 Failurecode[DWN8KB]GroundFaultofDetentSolenoid(Bucket).......................................40-785 Failurecode[DWN8KY]HotShortofDetentSolenoid(Bucket)............................................40-787 Failurecode[DX16KA]DisconnectionofRad.FanPumpEPCSol.......................................40-789 Failurecode[DX16KB]GroundFaultofRad.FanPumpEPCSol........................................40-791 Failurecode[DX16KY]HotShortofRadiatorFanPumpEPCSol........................................40-793 Failurecode[DXA1KA]DisconnectionofLoaderPumpEPCSolenoid.................................40-795 Failurecode[DXA1KB]GroundFaultofLoaderPumpEPCSolenoid...................................40-797 Failurecode[DXA1KY]HotShortofLoaderPumpEPCSolenoid........................................40-799 Failurecode[DXANKA]DisconnectionofSteeringPumpEPCSol.......................................40-801 Failurecode[DXANKB]GroundFaultofSteeringPumpEPCSolenoid................................40-803 Failurecode[DXANKY]HotShortofSteeringPumpEPCSolenoid......................................40-805 Failurecode[DXH1KA]DisconnectionofECMVSolenoid(Lockup).....................................40-806 Failurecode[DXH1KB]GroundFaultofECMVSolenoid(Lockup).......................................40-808 Failurecode[DXH1KY]HotShortofECMVSolenoid(Lockup)............................................40-810 Failurecode[DXH4KA]DisconnectionofECMVSolenoid(1st)............................................40-812
Failurecode[DXH4KB]GroundFaultofECMVSolenoid(1st).............................................40-814
Failurecode[DXH4KY]HotShortofECMVSolenoid(1st)...................................................40-816
Failurecode[DXH5KA]DisconnectionofECMVSolenoid(2nd)...........................................40-818
Failurecode[DXH5KB]GroundFaultofECMVSolenoid(2nd)............................................40-820
Failurecode[DXH5KY]HotShortofECMVSolenoid(2nd)..................................................40-822
Failurecode[DXH6KA]DisconnectionofECMVSolenoid(3rd)...........................................40-824
Failurecode[DXH6KB]GroundFaultofECMVSolenoid(3rd).............................................40-826
Failurecode[DXH6KY]HotShortofECMVSolenoid(3rd)..................................................40-828
Failurecode[DXH7KA]DisconnectionofECMVSolenoid(Reverse)....................................40-830
Failurecode[DXH7KB]GroundFaultofECMVSolenoid(Reverse).....................................40-832
Failurecode[DXH7KY]HotShortofECMVSolenoid(Reverse)...........................................40-834
Failurecode[DXH8KA]DisconnectionofECMVSolenoid(Forward)....................................40-836
Failurecode[DXH8KB]GroundFaultofECMVSolenoid(Forward)......................................40-838
Failurecode[DXH8KY]HotShortofECMVSolenoid(Forward)...........................................40-840
Failurecode[DXHHKA]DisconnectionofECMVSolenoid(4th)...........................................40-842
Failurecode[DXHHKB]GroundFaultofECMVSolenoid(4th).............................................40-844
Failurecode[DXHHKY]HotShortofECMVSolenoid(4th)..................................................40-846
Failurecode[DXHJKA]Disconnectionof3rdEPCSolenoid(EXT).......................................40-848
Failurecode[DXHJKB]GroundFaultof3rdEPCSolenoid(EXT).........................................40-850
Failurecode[DXHJKY]HotShortof3rdEPCSolenoid(EXT)..............................................40-852
Failurecode[DXHKKA]Disconnectionof3rdEPCSolenoid(RET)......................................40-854
Failurecode[DXHKKB]GroundFaultof3rdEPCSolenoid(RET)........................................40-856
Failurecode[DXHKKY]HotShortof3rdEPCSolenoid(RET).............................................40-858
Failurecode[DY30MA]Malfunction1ofEmerg.SteeringMotor...........................................40-860
Failurecode[DY30MC]Malfunction2ofEmerg.SteeringMotor..........................................40-863
Failurecode[DY30ME]Emerg.SteeringLong-TimeActivated.............................................40-867
Failurecode[LA00L3]FailureofFanReverse....................................................................40-869
Troubleshootingofelectricalsystem(E-mode)..........................................................................40-870
E-1Enginedoesnotstart..................................................................................................40-870
E-2Manualpreheatingsystemdoesnotwork.....................................................................40-876
E-3Automaticpreheatingsystemdoesnotwork.................................................................40-879
E-4Whilepreheatingisworking,preheatingmonitordoesnotlightup..................................40-881
E-5AllofLCDunit,LEDunit,andmeterunitonmachinemonitordisplaynothing..................40-883
E-6LCDunitonmachinemonitordisplaysnothing..............................................................40-886
E-7BacklightofLCDunitonmachinemonitorisabnormal(Backlightgoesoutor flickers)..............................................................................................................40-888
E-8LCDonmachinemonitordoesnotdisplayproperly.......................................................40-890
E-9Meterunitdisplayonmachinemonitorisabnormal.......................................................40-892
E-10Nightlightinglampofmeterunitonmachinemonitorisabnormal.................................40-895
E-11CautionLEDonmachinemonitorisabnormal.............................................................40-898
E-12LEDofswitchpanelonmachinemonitorisabnormalorswitchesdoesnotoperate properly.............................................................................................................40-900
E-13Twoswitchesoperationofswitchpanelonmachinemonitordoesnotfunction..............40-902
E-14Switchpanelbuzzerofmachinemonitorisabnormal...................................................40-905
E-15Rearviewmonitordoesnotlightuporbacklightflickers...............................................40-907
E-16Rearviewmonitorimagesarenotdisplayedclearly.....................................................40-910
E-17Rearviewmonitorbrightnesscannotbeadjusted........................................................40-913
E-18Nightlightinglampofrearviewmonitorisabnormal....................................................40-916
E-19Someitemsofgaugesandcautionlampsonmachinemonitorarenotdisplayed properly.............................................................................................................40-918
E-20ParkingbrakeindicatorlampdoesnotlightwhentheparkingbrakeissettoON(Parking) position..............................................................................................................40-919
E-21Whenbrakeaccumulatoroilpressuredrops,thebrakeoilpressurecautionlampdoesnot light...................................................................................................................40-923
E-22Aircleanercloggingindicatorlampdoesnotlight........................................................40-925
E-23Radiatorcoolantlevelcautionlampdoesnotlight.......................................................40-926
E-24Indicationofhydraulicoiltemperaturegaugedoesnotincrease,orhydraulicoil temperaturecautionlampdoesnotlight................................................................40-928
E-25Indicationoftorqueconverteroiltemperaturegaugedoesnotincrease,ortorque converteroiltemperaturecautionlampdoesnotlight.............................................40-930
E-26Fuellevelgaugedoesnotindicatecorrectlevel..........................................................40-931
E-27Seatbeltcautionlampindicationisabnormal..............................................................40-933
E-28Horndoesnotsound................................................................................................40-934
E-29Horndoesnotstopsounding.....................................................................................40-937
E-30Alarmbuzzerdoesnotsound....................................................................................40-939
E-31WhenstartingswitchisinONposition,alarmbuzzerdoesnotstopsounding................40-940
E-32KickdowndoesnotworkwhenkickdownswitchisturnedON.......................................40-941
E-33Theholdswitchdoesnotworkwhenitispressed........................................................40-943
E-34Parkingbrakedoesnotworkevenifitisapplied,orthebrakedragswhenparkingbrake isreleasedandFRdriveisoperated.....................................................................40-945
E-35Transmissioncut-offmodeisnotselectedornotreleased............................................40-948
E-36Transmissioncut-offsettingcannotbereleased..........................................................40-950
E-37Directionalselector(FNR)switchmodeisnotselectedornotreleased.........................40-952
E-38Whenoperatingenginepowerselectionswitch,enginepowerselectionfunctiondoesnot operateproperly.................................................................................................40-954
E-39Flowofloaderpumpdoesnotincreasefromtheminimumrate.....................................40-956
E-40ECSSfunctioncannotbeselectedorcannotbereleased............................................40-957
E-41Noneofheadlamp,clearancelamp,andtaillamplights...............................................40-959
E-42Clearancelampandtaillampdonotlightuporgoout.................................................40-961
E-43BothHighandLowbeamsofheadlampdonotlightuporgoout..................................40-964
E-44Lowbeamofheadlampdoesnotlightuporgoout......................................................40-968
E-45Highbeamofheadlampdoesnotlightuporgoout.....................................................40-970
E-46Frontworkinglampdoesnotlightuporgoout............................................................40-972
E-47Rearworkinglampdoesnotlightuporgoout.............................................................40-975
E-48Allofturnsignallampsandhazardlampsdonotlightuporgoout................................40-978
E-49Turnsignallampsdonotlightuporgoout..................................................................40-981
E-50Hazardlampdoesnotlightuporgoout......................................................................40-984
E-51Brakelampdoesnotlightorstayslighted...................................................................40-987
E-52Backuplampdoesnotlightupordoesnotgoout........................................................40-990
E-53Backupbuzzerdoesnotsoundorcontinuestosound.................................................40-993
E-54Frontwiperdoesnotoperate.....................................................................................40-995
E-55Rearwiperdoesnotoperate.....................................................................................40-998
E-56Windowwasherdoesnotoperate............................................................................40-1000
E-57Fuelfeedpumpdoesnotoperateorstopautomatically.............................................40-1003
E-58KOMTRAXsystemdoesnotoperateproperly...........................................................40-1005
Troubleshootingofhydraulicandmechanicalsystem(H-mode)................................................40-1007
Informationdescribedintroubleshootingtable(H-mode)...................................................40-1007
Systemchartofhydraulicandmechanicalsystems...........................................................40-1008
Failuremodeandcausetable..........................................................................................40-1011
H-1Machinedoesnotmoveoff.......................................................................................40-1019
H-2Torqueconverterlockupclutchisnotdisengaged(enginestalls)..................................40-1022
H-3Torqueconverterlockupclutchisnotengaged...........................................................40-1023
H-4Travelspeedisslow,bucketthrustforceisweak,gradabilityislow,orgearspeeddoesnot shift.................................................................................................................40-1024
H-5Largeshockismadewhenmachinestartsorgearisshifted........................................40-1027
H-6Machinestartsorgearspeedshiftswithlongtimelag.................................................40-1029
H-7Torqueconverteroiltemperatureishigh.....................................................................40-1031
H-8Machinedoesnotturn..............................................................................................40-1033
H-9Turningresponseispoor..........................................................................................40-1035
H-10Steeringwheelisheavytoturn................................................................................40-1037
H-11Machineswaysorlargeshocksaremadewhilemachineturns..................................40-1038
H-12Turningradiusdiffersbetweenrightandleftturns......................................................40-1040
H-13Wheelbrakesdonotworkorareweak.....................................................................40-1041
H-14Wheelbrakesarenotreleasedordrag.....................................................................40-1043
H-15Parkingbrakedoesnotworkoritisweak.................................................................40-1044
H-16Parkingbrakeisnotreleasedordrags(includingemergencyreleasesystem).............40-1045
H-17Boomdoesnotrise................................................................................................40-1046
H-18Boommovessloworboomlacksliftingforce............................................................40-1048
H-19Risingboomslowsdownatcertainheight................................................................40-1050
H-20Liftcylindersdonotservetoholdbucketonground..................................................40-1051
H-21Hydraulicdriftofboomislarge................................................................................40-1052
H-22Boommovesupanddownduringoperation.............................................................40-1053
H-23Bucketdoesnottiltback.........................................................................................40-1054
H-24Bucketmovessloworlackstilt-backforce................................................................40-1056
H-25Bucketdeceleratesduringtilt-backoperation............................................................40-1058
H-26Bucketcylinderdoesnotholdbucketonground.......................................................40-1059
H-27Hydraulicdriftofbucketislarge...............................................................................40-1060
H-28Buckettiltsbackandforthduringcarryingload(workequipmentvalvein HOLD).............................................................................................................40-1061
H-29Boomandbucketcontrolleversdonotmovesmoothlyandareheavytomove...........40-1062
H-30Operatingworkequipmentcausesenginespeedtolowersignificantlyorengineto stall.................................................................................................................40-1063
H-31Largeshocksaremadewhenworkequipmentstartstomoveandstops.....................40-1064
H-32Whencertainworkequipmentstallshydraulically,otherworkequipment moves.............................................................................................................40-1066
H-33E.C.S.S.(traveldamper)doesnotworkandmachinepitchesandbounces.................40-1067
H-34Bucketdoesnotstopatthepositionwhichissetwithremotebucketpositioner...........40-1068
H-35Fanspeedisabnormal(toohighorlow,orfandoesnotrotate)..................................40-1069
H-36Unusualnoiseisheardfromaroundfan...................................................................40-1070
Troubleshootingofengine(S-mode).......................................................................................40-1071
Informationmentionedintroubleshootingtable(Smode)...................................................40-1071
S-1WhenstartingswitchisturnedtoSTARTposition,engineisnotcranked.......................40-1072
S-2Theenginecranksbutexhaustsmokedoesnotcomeout...........................................40-1073
S-3Fuelisinjectedbutenginedoesnotstart(incompletecombustion,engineseemstostart but does not)...........................................................................................................................................................40-1074
S-4Enginestartabilityispoor......................................................................................................................40-1075
S-5Enginedoesnotpick-upsmoothly......................................................................................................40-1077
S-6Enginestopsduringoperation.............................................................................................................40-1079
S-7Enginerunsroughorisunstable.........................................................................................................40-1081
S-8Enginelackspower.................................................................................................................................40-1082
S-9KDPFgetscloggedinashorttime.......................................................................................................40-1084
S-10Engineoilconsumptionisexcessive.................................................................................................40-1086
S-11Engineoilbecomescontaminatedearly............................................................................................40-1087
S-12Fuelconsumptionisexcessive............................................................................................................40-1088
S-13Oilisincoolant(orcoolantspurtsorcoolantlevelgoesdown)...................................................40-1089
S-14Oilpressuredrops.................................................................................................................................40-1090
S-15Fuelmixesintoengineoil....................................................................................................................40-1091
S-16Watermixesintoengineoil(milky)....................................................................................................40-1092
S-17Coolanttemperaturerisestoohigh(overheating)..........................................................................40-1093
S-18Unusualnoiseisheard........................................................................................................................40-1094
S-19Vibrationisexcessive............................................................................................................................40-1095
S-20Aircannotbebledfromfuelcircuit..................................................................................................40-1096
S-21Activeregenerationisexecutedfrequently.....................................................................................40-1097
S-22Activeregenerationtakesalongtime...............................................................................................40-1098
S-23Whitesmokeisexhaustedduringactiveregeneration..................................................................40-1099
50Disassemblyandassembly..............................................................................................................................................50-1 Tableofcontents............................................................................................................................................................50-2 Troubleshooting of Central Lubrication System (CLS).........................................................................................40-1101
Generalinformationondisassemblyandassembly.................................................................................................50-4
Howtoreadthismanual.....................................................................................................................................50-4
Coatingmaterialslist.............................................................................................................................................50-6
Specialtoolslist...................................................................................................................................................50-10
Sketchesofspecialtools....................................................................................................................................50-17
Engineandcoolingsystem........................................................................................................................................50-47
Removalandinstallationofsupplypumpassembly.....................................................................................50-47
Removalandinstallationo njectorassembly...............................................................................................50-53
Removalandinstallationo ueldoserassembly...........................................................................................50-61
Removalandinstallationofcylinderheadassembly.....................................................................................50-63
Removalandinstallationofenginehoodassembly.....................................................................................50-77
Removalandinstallationofgrilleassembly...................................................................................................50-79
Removalandinstallationofcoolingsystemassembly..................................................................................50-82
Removalandinstallationofradiatorcoreassembly......................................................................................50-85
Removalandinstallationofaftercooler............................................................................................................50-87
Removalandinstallationofhydraulicoilcooler............................................................................................50-90
Removalandinstallationofpowertrainoilcoolerassembly......................................................................50-92
Removalandinstallationofengineassembly................................................................................................50-96
Removalandinstallationofenginefrontoilseal.........................................................................................50-102
Removalandinstallationofenginerearoilseal...........................................................................................50-105
Removalandinstallationofcoolingfanandcoolingfanmotorassembly.............................................50-110
RemovalandinstallationofKDPFassembly.................................................................................................50-112
DisassemblyandassemblyofKDPFassembly.............................................................................................50-117
RemovalandinstallationofKCCVassembly................................................................................................50-126
RemovalandinstallationofKVGTassembly................................................................................................50-128
RemovalandinstallationofEGR(ExhaustGasRecirculation)valveassembly.......................................50-133
RemovalandinstallationofEGR(ExhaustGasRecirculation)coolerassembly.....................................50-134
Removalandinstallationofaircleanerassembly......................................................................................50-136
Removalandinstallationofairconditionercompressorbelt..................................................................50-138
Removalandinstallationofalternatorbelt.................................................................................................50-139
Removalandinstallationo ueltankassembly..........................................................................................50-140
Powertrain.................................................................................................................................................................50-143
Removalandinstallationoftorqueconverterandtransmissionassembly............................................50-143
Disassemblyandassemblyoftransmissionassembly................................................................................50-148
Disassemblyandassemblyoftorqueconverterassembly........................................................................50-178