Komatsu GALEO WA450-5L WA480-5L Wheel Loader Shop Manual PDF

Description

Komatsu GALEO WA450-5L WA480-5L Wheel Loader Shop Manual CEBM009605 – PDF DOWNLOAD

FILE DETAILS:

Komatsu GALEO WA450-5L WA480-5L Wheel Loader Shop Manual CEBM009605 – PDF DOWNLOAD 

Language : English
Pages : 1411
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu GALEO WA450-5L WA480-5L Wheel Loader Shop Manual CEBM009605 – PDF DOWNLOAD 

SERIAL NUMBERS
WA450-5L A36001  and UP
WA480-5L A37001  and UP

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

TABLE OF CONTENTS:

Komatsu GALEO WA450-5L WA480-5L Wheel Loader Shop Manual CEBM009605 – PDF DOWNLOAD 

SERIAL NUMBERS
WA450-5L A36001  and UP
WA480-5L A37001  and UP

MAIN MENU 0
COVER 1
CONTENTS 2
FOREWORD 15
SAFETY 15
SAFETY NOTICE 15
IMPORTANT SAFETY NOTICE 15
GENERAL PRECAUTIONS 15
PREPARATIONS FOR WORK 15
PRECAUTIONS DURING WORK 15
GENERAL 17
HOW TO READ THE SHOP MANUAL 18
VOLUMES 18
DISTRIBUTION AND UPDATING 18
FILING METHOD 18
REVISED EDITION MARK 18
REVISIONS 18
SYMBOLS 18
HOISTING INSTRUCTIONS 19
HOISTING 19
WIRE ROPES 19
PUSH PULL COUPLER 20
TYPE 1 20
TYPE 2 21
TYPE 3 22
COATING MATERIALS 23
STANDARD TIGHTENING TORQUE 25
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 25
TIGHTENING TORQUE OF HOSE NUTS 26
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 26
TIGHTENING TORQUE FOR FLARED NUTS 26
ELECTRIC WIRE CODE 27
CLASSIFICATION BY THICKNESS 27
CLASSIFICATION BY COLOR AND CODE 27
CONVERSION TABLES 28
METHOD OF USING THE CONVERSION TABLE 28
01 GENERAL 35
SPECIFICATIONS 36
WEIGHT TABLE 40
FUEL, COOLANT AND LUBRICANTS 41
10 STRUCTURE AND FUNCTION 43
RADIATOR AND OIL COOLER 51
SPECIFICATIONS 51
ENGINE AND TRANSMISSION MOUNT 52
POWER TRAIN 53
OUTLINE 53
POWER TRAIN SYSTEM DIAGRAM 54
WITHOUT TORQUE CONVERTER LOCK UP CLUTCH 54
WITH TORQUE CONVERTER LOCK UP CLUTCH 55
DRIVE SHAFT 57
DRIVE TRAIN PIPING 58
TORQUE CONVERTER 59
WITHOUT LOCK UP CLUTCH 59
SPECIFICATIONS 59
PATH OF POWER TRANSMISSION 61
WITH LOCK UP CLUTCH 62
SPECIFICATIONS 62
PATH OF POWER TRANSMISSION 66
TRANSMISSION 68
OUTLINE 73
CLUTCH AND REDUCTION GEAR RATIO TABLE 73
F & R CLUTCH WITHOUT LOCK UP CLUTCH 74
F & R CLUTCH WITH LOCK UP CLUTCH 75
1ST & 4TH CLUTCH 76
2ND & 3RD CLUTCH 77
OPERATION OF CLUTCH 78
CLUTCH ENGAGED 78
CLUTCH DISENGAGED 78
FORWARD 1ST 79
FORWARD 2ND 80
FORWARD 3RD 81
FORWARD 4TH 82
REVERSE 1ST 83
TRANSMISSION CONTROL VALVE 84
WITHOUT LOCK UP CLUTCH 84
ECMV ACTUATION TABLE 85
OUTLINE 85
WITH LOCK UP CLUTCH 86
ECMV ACTUATION TABLE 87
OUTLINE 87
ECMV – ELECTRONIC CONTROL MODULATION VALVE 88
ECMV FOR SPEED CLUTCH 89
ECMV FOR LOCK UP CLUTCH 92
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE 94
OUTLINE 95
OPERATION 95
FLOW VALVE 96
OPERATION 96
AXLES 97
FRONT AXLE 97
WA450-5L 97
WA480-5L 98
REAR AXLE 99
WA450-5L 99
WA480-5L 100
AXLE MOUNTING 101
FRONT AXLE 101
REAR AXLE 102
DIFFERENTIAL 103
LIMITED SLIP DIFFERENTIAL 103
WA450-5L FRONT 105
WA480-5L FRONT AND REAR 105
WA450-5L REAR 106
OPERATION 107
TRAVELING IN A STRAIGHT LINE 107
WHEN TURNING 108
STANDARD DIFFERNTIAL 109
FRONT DIFFERENTIAL 109
REAR DIFFERENTIAL 110
OUTLINE 111
TRAVELING IN A STRAIGHT LINE 111
TURNING 111
FINAL DRIVE 112
WA450-5L 112
WA480-5L 113
OUTLINE 115
CENTER HINGE PIN 116
OUTLINE 116
STEERING PIPING 119
STEERING COLUMN 120
STEERING VALVE 121
OVERLOAD RELIEF VALVE 122
FUNCTION 122
OPERATION 122
STEERING RELIEF VALVE 123
FUNCTION 123
OPERATION OF STEERING RELIEF VALVE 124
OPERATION OF DEMAND VALVE 125
FLOW AMP 128
OPERATION OF FLOW AMP 128
OPERATION OF STEERING VALVE 131
NEUTRAL 131
TURNING RIGHT 132
TURNING LEFT 133
ORBITROL VALVE 134
OUTLINE 135
STRUCTURE 135
CONNECTION BETWEEN HAND PUMP AND SLEEVE 136
STOP VALVE 138
STEERING AND SWITCH PUMP 139
OUTLINE 139
AUXILIARY STEERING PUMP 141
FUNCTION 141
AUXILIARY STEERING MOTOR 142
FUNCTION 142
SPECIFICATIONS 142
STEERING CYLINDER 143
MOUNTING 143
CYLINDER 144
JOYSTICK STEERING LEVER 145
LEVER CONNECTIONS 145
STEERING SWITCH VALVE 146
OPERATION 146
STEERING LEVER VALVE 147
BRAKE SYSTEM 148
PIPING 148
BRAKE VALVE 149
LEFT PEDAL AND VALVE 149
RIGHT PEDAL AND VALVE 150
OUTLINE 151
OPERATION 151
CHARGE VALVE 155
FUNCTION 156
OPERATION 157
ACCUMULATOR 159
BETWEEN CHARGE VALVE AND BRAKE VALVE 159
SPECIFICATIONS 159
BETWEEN BRAKE VALVE AND BRAKE CYLINDER 160
SLACK ADJUSTER 161
OUTLINE 162
SPECIFICATIONS 162
OPERATION 163
BRAKES 164
FRONT 164
REAR 165
PARKING BRAKE 167
CONTROLS 167
OUTLINE 167
BRAKE PORTION 168
OUTLINE 168
SOLENOID VALVE 169
PARKING BRAKE APPLIED 169
PARKING BRAKE RELEASED 169
RELEASE VALVE 170
OUTLINE 170
HYDRAULIC PIPING 171
OUTLINE 172
WORK EQUIPMENT CONTROL LEVER 173
FOR PPC VALVE 173
FOR EPC VALVE 174
HYDRAULIC TANK 175
SPECIFICATIONS 175
BREATHER 176
SPECIFICATIONS 176
PREVENTION OF NEGATIVE PRESSURE IN TANK 176
PREVENTION OF PRESSURE RISE IN TANK 176
CONVERTER, EQUIPMENT AND PPC PUMPS 177
SAL (4)125+140+(1)22 177
OUTLINE 177
PPC RELIEF VALVE 178
OUTLINE 178
OPERATION 178
ECSS VALVE 179
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM 179
TRAVEL DAMPER VALVE 181
EQUIPMENT CONTROL VALVE 182
2 SPOOL VALVE 182
3 SPOOL VALVE 185
RELIEF VALVE 188
FUNCTION 188
OPERATION 188
SAFETY SUCTION VALVE 189
FUNCTION 189
OPERATION 189
SUCTION VALVE 190
FUNCTION 190
OPERATION 190
SAFETY SUCTION VALVE 190
FUNCTION 190
OPERATION 190
CUT OFF VALVE 192
FUNCTION 192
CUT OFF VALVE OPERATION 192
FLOAT SELECTOR AND UNLOAD VALVE 194
FUNCTION 194
OPERATION 194
BOOM AND BUCKET SPOOL HOLD POSITION 195
OPERATION 195
BOOM SPOOL RAISE POSITION 196
OPERATION 196
BOOM SPOOL LOWER POSITION 197
OPERATION 197
BOOM SPOOL FLOAT POSITION 198
OPERATION 198
BUCKET SPOOL DUMP POSITION 199
OPERATION 199
BUCKET SPOOL TILT POSITION 200
OPERATION 200
PPC VALVE FOR TWO LEVERS 201
OPERATION 203
NEUTRAL 203
FINE CONTROL MODE 204
PPC VALVE FOR MONO LEVER 206
OPERATION 208
NEUTRAL 208
FINE CONTROL 209
FLOAT 210
FLOAT RELEASED 210
EPC VALVE 211
FUNCTION 212
OPERATION 212
SHUT OFF VALVE 214
FUNCTION 214
COOLING FAN 215
MOTOR MODEL: LMF28 215
SPECIFICATIONS 215
FUNCTION 217
PRINCIPLE OF OPERATION 217
SUCTION VALVE 218
FUNCTION 218
OPERATION 218
FAN DIRECTION CHANGEOVER VALVE 219
DRIVE PUMP – MODEL: LPV3O 220
FUNCTION 222
STRUCTURE 222
OPERATION 223
SERVO VALVE 224
FUNCTION 225
SAFETY VALVE 226
FUNCTION 226
BOOM AND BUCKET LINKAGE 227
BUCKET 229
BUCKET POSITIONER, BOOM KICK OUT 230
BUCKET POSITIONER 231
BOOM KICK OUT 231
OPERATION OF PROXIMITY SWITCH 231
BOOM RAISE 231
BUCKET TILT 233
WORK EQUIPMENT CYLINDER 236
BOOM CYLINDER 236
BUCKET CYLINDER 236
CAB 238
AIR CONDITIONER 239
MACHINE MONITORING SYSTEM 240
OUTLINE 240
MODE INDICATIONS 240
INDIVIDUAL CIRCUIT DIAGRAMS 242
STARTING AND LIGHTING 242
LOAD METER 242
SENSING FUNCTIONS 243
POWER SUPPLY AND NETWORK 244
MACHINE MONITOR 248
STANDARD STYLE 248
LOAD METER STYLE 249
TABLE OF MONITOR INDICATION ITEMS 250
SETTING OF THE MACHINE MONITOR 260
ADJUSTMENT PROCEDURES 262
SERVICE MODE FUNCTIONS 263
ITEMS RELATED TO THE FAULT HISTORY OF ELECTRIC SYSTEM 267
ITEMS RELATED TO THE FAULT HISTORY OF MACHINE SYSTEM 269
ITEMS RELATED TO MAINTENANCE MONITOR 271
ENGINE CYLINDER CUT OUT FUNCTION 273
REAL TIME MONITORING FUNCTION 275
REAL TIME MONITORING ITEMS 279
LOAD METER FUNCTION 290
OUTLINE 290
MACHINE SETTING 299
TRANSMISSION CONTROL SYSTEM 327
CONTROL FUNCTION 328
ELECTRIC CIRCUIT DIAGRAM – STD 352
ELECTRIC CIRCUIT DIAGRAM – OPT 354
TRANSMISSION CONTROLLER 356
INPUT AND OUTPUT SIGNALS 356
DEUTSCH-24P – CNL61 356
DEUTSCH-40P[1] – CNL62 357
DEUTSCH-40P[2] – CNL63 357
WORK EQUIPMENT CONTROL SYSTEM 358
SYSTEM DIAGRAM 358
WORK EQUIPMENT CONTROL 359
ELECTRIC LEVER CONTROL 359
DETENT CONTROL 360
REMOTE POSITIONER CONTROL 362
FUNCTIONS 362
STOP THE BOOM RAISE OPERATION 362
CONTROL ITEMS 364
SEMI AUTO DIG CONTROL 365
STARTING CONDITIONS FOR SEMI AUTO DIG 366
STARTING SEMI AUTO DIG 366
TERMINATION OF SEMI AUTO DIG 366
SEMI AUTO DIG MODE 367
JOYSTICK STEERING CONTROL 368
STEERING CONTROL 369
MODULATION CONTROL 369
CALIBRATION FUNCTION 370
ELECTRIC CIRCUIT DIAGRAM 371
WORK EQUIPMENT CONTROLLER 373
INPUT AND OUTPUT SIGNALS 373
DEUTSCH-24P – CNL71 373
DEUTSCH-40P[1] – CNL72 374
DEUTSCH-40P[2] – CNL73 374
ELECTRIC TRANSMISSION CONTROL 375
FUNCTIONS 376
COMBINATION SWITCH 377
FUNCTIONS 377
OVERVIEW 377
OPERATION 378
KICK DOWN HOLD SWITCH 379
FUNCTIONS 379
ENGINE START CIRCUIT 380
FUNCTION 380
OPERATION 381
ENGINE STOP CIRCUIT 382
OPERATION 382
PARKING BRAKE CIRCUIT 383
OPERATION 383
STARTING SWITCH IN OFF POSITION 383
STARTING SWITCH IN ON POSITION 383
TURN SIGNAL AND HAZARD LAMP CIRCUIT 385
OPERATION 385
STARTING SWITCH IN OFF POSITION 385
STARTING SWITCH IN ON POSITION 385
BACK UP LAMP AND STOP LAMP CIRCUIT 387
OPERATION 387
STOP LAMP CIRCUIT 387
BACK UP LAMP CIRCUIT 388
SMALL LAMP AND HEAD LAMP CIRCUIT 389
OPERATION 389
WORK LAMP CIRCUIT 390
OPERATION 390
HORN CIRCUIT 391
OPERATION 391
WIPER WASHER CIRCUIT 392
OPERATION 392
FRONT WIPER CIRCUIT 392
REAR WIPER CIRCUIT 393
SENSORS 394
ENGINE AND MACHINE SPEED SENSOR 394
FUNCTION 394
ENGINE OIL PRESSURE SENSOR 394
FUNCTION 394
ENGINE OIL LEVEL SENSOR 395
FUNCTION 395
TEMPERATURE SENSOR 395
ENGINE COOLANT, CONVERTER, HYDRAULIC, TRANSMISSION OR BRAKE OIL 395
TRANSMISSION CUT OFF PRESSURE SENSOR 396
FUNCTION 396
RADIATOR COOLANT LEVEL SENSOR 397
FUNCTION 397
FUEL LEVEL SENSOR 398
FUNCTION 398
BOOM ANGLE SENSOR FOR LOAD METER 399
FUNCTION 399
AIR CLEANER CLOGGING SENSOR 400
FUNCTION 400
PRESSURE SENSOR FOR LOAD METER 400
FUNCTION 400
BATTERY LIQUID SENSOR 401
FUNCTION 401
RELAYS 402
20 TESTING, ADJUSTING AND TROUBLESHOOTING 403
STANDARD VALUE TABLE FOR ENGINE 405
STANDARD VALUE TABLE FOR CHASSIS 406
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 413
ENGINE COMPONENTS 415
MEASURING EXHAUST SMOKE 415
MEASURING EXHAUST TEMPERATURE 415
ADJUSTING VALVE CLEARANCE 415
MEASURING COMPRESSION PRESSURE 415
MEASURING CRANCASE PRESSURE 415
MEASURING ENGINE OIL PRESSURE 415
MEASURING BOOST PRESSURE 415
MEASURING FUEL PRESSURE 415
ADJUSTING ENGINE SPEED SENSOR 415
BLEEDING AIR FROM FUEL SYSTEM 415
MEASURING ENGINE SPEED 416
ADJUSTING ACCELERATOR PEDAL 418
POTENTIOMETER 418
MICROSWITCH 420
ADJUSTING TRANSMISSION SPEED SENSOR 421
POWER TRAIN OIL PRESSURE 422
FLUSHING 426
TORQUE CONVERTER, TRANSMISSION AND HYDRAULIC CIRCUIT 426
TRANSMISSION VALVE FAILS 427
MOVING MACHINE 427
STEERING CONTROL 429
STEERING OIL PRESSURE 430
BRAKE SYSTEM 432
MEASURING BRAKE OIL PRESSURE 432
TESTING WEAR OF WHEEL BRAKE DISC 434
BLEEDING AIR FROM BRAKE CIRCUIT 435
TESTING WEAR OF PARKING BRAKE DISC 436
MANUAL RELEASE METHOD FOR PARKING BRAKE 437
TESTING HYDRAULIC FAN 438
ACCUMULATOR CHARGE PRESSURE 439
PPC OIL PRESSURE 441
WORK EQUIPMENT HYDRAULIC PRESSURE 444
BUCKET POSITIONER 446
LIFT ARM KICK-OUT 447
PROXIMITY SWITCH ACTUATION 448
ADJUSTING MACHINE MONITOR 449
LOAD METER 452
LOAD METER CALIBRATION 453
NO LOAD ZERO POINT ADJUSTMENT (SUPPLEMENTAL EXPLANATIONS) 453
LOAD ZERO POINT ADJUSTMENT (SUPPLEMENTARY EXPLANATIONS) 454
BLEEDING AIR 457
RELEASING REMAINING PRESSURE 458
IN HYDRAULIC CIRCUIT 458
IN TRAVEL DAMPER CIRCUIT 459
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT 460
PM-CLINIC INSPECTION TABLE 461
TROUBLESHOOTING GENERAL 465
POINTS TO REMEMBER WHEN TROUBLESHOOTING 466
SEQUENCE OF EVENTS IN TROUBLESHOOTING 468
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 469
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT 469
HANDLING CONTROL BOX 474
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 475
CHECKS BEFORE TROUBLESHOOTING 477
EQUIPMENT FOR TROUBLESHOOTING ELECTRICAL SYSTEM 478
TROUBLESHOOTING MACHINE MONITOR 479
SPECIAL FUNCTIONS OF MACHINE MONITOR 480
FLOW OF MODES AND FUNCTIONS 481
FAILURE CODE TABLE 489
MONITORING CODE TABLE 503
USING TROUBLESHOOTING CHARTS 515
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 522
T-ADAPTER TABLE 543
TROUBLESHOOTING OF ENGINE CONTROL SYSTEM (ENG MODE) 547
CONNECTOR TYPES AND INSTALLATION LOCATIONS 550
CONNECTOR ARRANGEMENT LOCATIONS 557
ENGINE CONTROL SYSTEM DIAGRAM 563
ERROR CODE [A000N1] 565
ENGINE OVERRUNS (N1) 565
ERROR CODE [AD00L2] 566
COMMON RAIL HIGHER THAN SET VALUE 566
ERROR CODE [AD10L3] 567
FUEL SUPPLY PUMP CANNOT BE CONTROLLED 567
ERROR CODE [AD00MA] 570
FUNCTION OF COMMON RAIL IS DEFECTIVE 570
ERROR CODE [AD10MA] 571
FUEL SUPPLY PUMP IS DEFECTIVE 571
ERROR CODE [AD10MB] 572
FUEL SUPPLY PUMP FLOW LOWERED 572
ERROR CODE [AD11KA or AD11KB] 573
OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM 573
ERROR CODE [AD51KA or AD51KB] 575
OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM 575
ERROR CODE [ADA1KA] 577
OPEN IN NO 1 INJECTOR SOLENOID VALVE 577
ERROR CODE [ADAZKB] 579
SHORT CIRCUIT IN NO 1, 2, 3 INJECTOR SOLENOID VALVE 579
ERROR CODE [ADB1KA] 581
OPEN IN NO 2 INJECTOR SOLENOID VALVE 581
ERROR CODE [ADC1KA] 583
OPEN IN NO 3 INJECTOR SOLENOID VALVE 583
ERROR CODE [ADD1KA] 585
OPEN IN NO 4 INJECTOR SOLENOID VALVE 585
ERROR CODE [ADDZKB] 587
SHORT CIRCUIT IN NO 4, 5, 6 INJECTOR SOLENOID VALVE 587
ERROR CODE [ADE1KA] 589
OPEN IN NO 5 INJECTOR SOLENOID VALVE 589
ERROR CODE [ADF1KA] 591
OPEN IN NO 6 INJECTOR SOLENOID VALVE 591
ERROR CODE [D182KZ] 593
OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL 593
ERROR CODE [D1D0KB] 595
SHORT CIRCUIT IN VOLTAGE LOAD POWER SUPPLY 595
ERROR CODE [DB20KT] 597
CONTROLLER POWER SUPPLY (NSW) VOLTAGE IS LOW 597
ERROR CODE [AB20KT] 599
TROUBLE IN DRIVE CIRCUIT IN CONTROLLER 599
ERROR CODE [DB22KK] 601
ENGINE CONTROLLER LOAD POWER SUPPLY (SW) 1 601
ERROR CODE [DB29KQ] 603
NONCONFORMANCE OF MODEL SELECTION SIGNALS IN ENGINE CONTROLLER CONNECTING WIRING HARNESS 603
ERROR CODE [DB2AMA] 605
FUNCTION OF Q ADJUSTMENT SWITCH OF ENGINE CONTROLLER IS DEFECTIVE 605
ERROR CODE [DD11KB] 606
TROUBLE IN INPUT OF STARTING SWITCH C (IGN C1) 606
ERROR CODE [DGE3L6] 608
TROUBLE IN WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM 608
ERROR CODE [DGE4KX] 610
TROUBLE IN FUEL TEMPERATURE SENSOR SYSTEM 610
ERROR CODE [DH30KX] 612
TROUBLE IN BOOST PRESSURE SENSOR SYSTEM 612
ERROR CODE [DH40KX] 614
TROUBLE IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM 614
ERROR CODE [DK10KX] 616
TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM 616
ERROR CODE [DLE3LC] 618
TROUBLE IN ENGINE NE SPEED SENSOR SYSTEM 618
ERROR CODE [DLH1LC] 619
TROUBLE IN ENGINE G SPEED SENSOR SYSTEM 619
ERROR CODE [ENG-1] 620
ENGINE DOES NOT START 620
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE) 625
CONNECTOR TYPES AND INSTALLATION POSITIONS 631
CONNECTOR LAYOUT DRAWING 638
TRANSMISSION RELATED SYSTEM DIAGRAM 644
ERROR CODE [1500L1] 647
DOUBLE ENGAGEMENT DETECTED 647
ERROR CODE [15SAL1] 648
F-ECMV FILL SWITCH SYSTEM SHORTED 648
ERROR CODE [15SALH] 649
F_ECMV FILL SWITCH SYSTEM OPEN 649
ERROR CODE [15SBL1] 650
R_ECMV FILL SWITCH SYSTEM SHORTED 650
ERROR CODE [15SBLH] 652
R_ECMV FILL SWITCH SYSTEM OPEN 652
ERROR CODE [15SEL1] 653
1ST_ECMV FILL SWITCH SYSTEM SHORTED 653
ERROR CODE [15SELH] 655
1ST_ECMV FILL SWITCH SYSTEM OPEN 655
ERROR CODE [15SFL1] 657
2ND_ECMV FILL SWITCH SYSTEM SHORTED 657
ERROR CODE [15SFLH] 659
2ND_ECMV FILL SWITCH SYSTEM OPEN 659
ERROR CODE [15SGL1] 661
3RD_ECMV FILL SWITCH SYSTEM SHORTED 661
ERROR CODE [15SGLH] 663
3RD_ECMV FILL SWITCH SYSTEM OPEN 663
ERROR CODE [15SHL1] 665
4TH_ECMV FILL SWITCH SYSTEM SHORTED 665
ERROR CODE [15SHLH] 667
4TH_ECMV FILL SWITCH SYSTEM OPEN 667
ERROR CODE [15SJL1] 669
LOCKUP_ECMV FILL SWITCH SYSTEM SHORTED 669
ERROR CODE [15SJLH] 670
LOCKUP_ECMV FILL SWITCH SYSTEM OPEN 670
ERROR CODE [989F00] 671
TRANSMISSION PROTECTION CAUTION 671
ERROR CODE [989G00] 672
FNR LEVER PRIORITY CAUTION 672
ERROR CODE [B@C7NS] 673
REAR BRAKE COOLING OIL OVERHEATING FAULT 673
ERROR CODE [D150KA] 675
EMERGENCY STEERING RELAY OUTPUT SYSTEM OPEN 675
ERROR CODE [D150KB] 676
EMERGENCY STEERING RELAY OUTPUT SYSTEM SHORTED 676
ERROR CODE [D160KA] 677
EMERGENCY STEERING RELAY OUTPUT SYSTEM OPEN 677
ERROR CODE [D160KB] 678
BACKUP LAMP RELAY OUTPUT SYSTEM SHORTED 678
ERROR CODE [D191KA] 679
NEUTRAL SAFETY RELAY OUTPUT SYSTEM OPEN 679
ERROR CODE [D191KB] 681
NEUTRAL SAFETY RELAY OUTPUT SYSTEM SHORTED 681
ERROR CODE [D192KA] 683
BOOM DAMPER RELAY OUTPUT SYSTEM OPEN 683
ERROR CODE [D192KB] 684
LIFT ARM DAMPER RELAY OUTPUT SYSTEM SHORTED 684
ERROR CODE [DAQ0KK] 685
CONTROLLER POWER SUPPLY FAULT 685
ERROR CODE [DAQ2KK] 686
DEFECTIVE SOLENOID POWER SUPPLY SYSTEM 686
ERROR CODE [DAQ9KQ] 688
MODEL SELECTION SIGNAL MISMATCH 688
ERROR CODE [DDK3KA] 689
RIGHT FNR SIGNAL INPUT FAULT 689
ERROR CODE [DDK3KB] 691
MULTIPLE RIGHT FNR SIGNAL INPUT FAULTS 691
ERROR CODE [DDK6KA] 693
FORWARD-REVERSE LEVER SIGNAL FAULT 693
ERROR CODE [DDK6KB] 695
MULTIPLE FORWARD-REVERSE LEVER SIGNAL INPUT FAULT 695
ERROR CODE [DDS5KA] 697
STEERING PRESSURE SWITCH OPEN 697
ERROR CODE [DDS5KB] 698
STEERING PRESSURE SWITCH SHORTED 698
ERROR CODE [DDT0L4] 700
MANUAL/AUTO-SHIFT SELECTOR SWITCH SELECTION FAILURE 700
ERROR CODE [DDT4LD] 702
GROUND FAULT ON TRANSMISSION CUT-OFF SETTING SWITCH 702
ERROR CODE [DDW9LD] 703
SHORT IN KICKDOWN SWITCH SYSTEM 703
ERROR CODE [DDWLLD] 704
GROUND FAULT IN HOLD SWITCH SYSTEM 704
ERROR CODE [DF10KA] 705
NO INPUT IN GEAR SHIFT LEVER SYSTEM 705
ERROR CODE [DF10KB] 707
MULTIPLE GEAR SHIFT LEVER SIGNALS OR NO GEAR SHIFT LEVER SIGNAL 707
ERROR CODE [DGF1KX] 709
TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM FAILURE 709
ERROR CODE [DGR2KA] 710
REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM OPEN 710
ERROR CODE [DGR2KB] 712
GROUND FAULT IN REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM 712
ERROR CODE [DHT1KX] 713
TRANSMISSION CUT-OFF (LEFT BRAKE PRESSURE SENSOR) SIGNAL OPEN 713
ERROR CODE [DLE2KA] 714
ENGINE SPEED SENSOR OPEN 714
ERROR CODE [DLE2LC] 715
ENGINE SPEED SENSOR SHORTED 715
ERROR CODE [DLT3KA] 716
SPEED SENSOR SYSTEM OPEN 716
ERROR CODE [DT20KB] 717
GROUND FAULT IN BUILT-IN INDICATOR LAMP SYSTEM ON TRANSMISSION CUT-OFF SWITCH 717
ERROR CODE [DW7BKA] 718
FAN REVERSE SOLENOID SYSTEM OPEN 718
ERROR CODE [DW7BKB] 719
FAN REVERSE SOLENOID SYSTEM SHORTED 719
ERROR CODE [DW7CKA] 720
SWITCH PUMP CUT-OFF RELAY OPEN 720
ERROR CODE [DW7CKB] 721
SWITCH PUMP CUT-OFF RELAY GROUND FAULT 721
ERROR CODE [DX16KA] 722
FAN PUMP EPC SOLENOID SYSTEM OPEN 722
ERROR CODE [DX16KB] 723
FAN PUMP EPC SOLENOID SYSTEM GROUND FAULT 723
ERROR CODE [DXH1KA] 724
LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM OPEN 724
ERROR CODE [DXH1KB] 725
LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM SHORTED 725
ERROR CODE [DXH4KA] 726
1ST_ECMV SOLENOID SYSTEM OPEN 726
ERROR CODE [DXH4KB] 727
1ST_ECMV SOLENOID SYSTEM SHORTED 727
ERROR CODE [DXH5KA] 728
2ND_ECMV SOLENOID SYSTEM OPEN 728
ERROR CODE [DXH5KB] 729
2ND_ECMV SOLENOID SYSTEM SHORTED 729
ERROR CODE [DXH6KA] 730
3RD_ECMV SOLENOID SYSTEM OPEN 730
ERROR CODE [DXH6KB] 731
3RD_ECMV SOLENOID SYSTEM SHORTED 731
ERROR CODE [DXH7KA] 732
R_ECMV SOLENOID SYSTEM OPEN 732
ERROR CODE [DXH7KB] 733
R_ECMV SOLENOID SYSTEM GROUND FAULT 733
ERROR CODE [DXH8KA] 734
F_ECMV SOLENOID SYSTEM OPEN 734
ERROR CODE [DXH8KB] 735
F_ECMV SOLENOID SYSTEM GROUND FAULT 735
ERROR CODE [DXHHKA] 736
4TH_ECMV SOLENOID SYSTEM OPEN 736
ERROR CODE [DXHHKB] 737
4TH_ECMV SOLENOID SYSTEM SHORTED 737
ERROR CODE [DY30MA] 738
MOTOR DRIVEN EMERGENCY STEERING PUMP ERROR (MALFUNCTION IN MANUAL MODE) 738
ERROR CODE [DY30MC] 740
MOTOR DRIVEN EMERGENCY STEERING PUMP ERROR (MALFUNCTION IN MANUAL MODE) 740
ACTION CODE [TM-1] 742
OPEN OR SHORT IN KICKDOWN SWITCH SYSTEM 742
ACTION CODE [TM-2] 744
OPEN OR SHORT IN HOLD SWITCH (NO HOLD CONTROL PERFORMED BY PRESSING HOLD SWITCH) 744
ACTION CODE [TM-3] 746
TORQUE CONVERTER LOCK-UP SWITCH SYSTEM FAILURE (NO LOCK-UP PERFORMED OR NO LOCK-UP CANCELLATION PERFORMED) 746
ACTION CODE [TM-4] 748
NEUTRALIZER SIGNAL (PARKING BRAKE SWITCH SIGNAL) SYSTEM FAILURE 748
ACTION CODE [TM-5] 750
EMERGENCY STEERING SWITCH (MOTOR DRIVEN EMERGENCY STEERING OPERATION SWITCH) SIGNAL SYSTEM FAILURE 750
ACTION CODE [TM-6] 752
OPEN OR SHORT IN TRANSMISSION CUT-OFF SWITCH SYSTEM 752
ACTION CODE [TM-7] 753
OPEN OR SHORT IN TRANSMISSION CUT-OFF SETTING SWITCH SYSTEM 753
ACTION CODE [TM-8] 754
TRANSMISSION CUT-OFF (LEFT BRAKE SENSOR) SIGNAL SHORTED 754
ACTION CODE [TM-9-A] 755
JOYSTICK SHIFT UP/SHIFT DOWN SWITCH SYSTEM FAILURE 755
ACTION CODE [TM-9-B] 757
FNR SWITCH MODE CHANGE OVER SWITCH SYSTEM FAILURE 757
ACTION CODE [TM-10] 759
START SWITCH “C” (IGN C) SIGNAL SYSTEM FAILURE 759
ACTION CODE [TM-11] 761
JOYSTICK ON/OFF CHANGE OVER SWITCH SYSTEM FAILURE 761
ACTION CODE [TM-12] 763
OPEN OR SHORT IN ENGINE POWER MODE SWITCH 763
ACTION CODE [TM-13] 764
OPEN OR SHORT IN TRAVEL DAMPER ON/OFF SWITCH 764
ACTION CODE [TM-14] 765
OPEN OR SHORT IN HYDRAULIC FAN REVERSE SWITCH SIGNAL SYSTEM 765
ACTION CODE [TM-15] 767
SHORT IN MOTOR DRIVEN EMERGENCY STEERING RELAY OUTPUT SYSTEM 767
ACTION CODE [TM-16] 768
SHORT IN TRAVEL DAMPER RELAY OUTPUT SYSTEM 768
ACTION CODE [TM-17] 769
SWITCH PUMP CUT-OFF RELAY OUTPUT SYSTEM SHORTED 769
ACTION CODE [TM-18] 770
BACK LAMP RELAY OUTPUT SYSTEM SHORTED 770
ACTION CODE [TM-19] 771
NEUTRAL OUTPUT SYSTEM SHORTED 771
ACTION CODE [TM-20] 773
F_ECMV SOLENOID SYSTEM SHORTED 773
ACTION CODE [TM-21] 774
R_ECMV SOLENOID SYSTEM SHORTED 774
ACTION CODE [TM-22] 775
1ST_ECMV SOLENOID SYSTEM SHORTED 775
ACTION CODE [TM-23] 776
2ND_ECMV SOLENOID SYSTEM SHORTED 776
ACTION CODE [TM-24] 777
3RD_ECMV SOLENOID SYSTEM SHORTED 777
ACTION CODE [TM-25] 778
4TH_ECMV SOLENOID SYSTEM SHORTED 778
ACTION CODE [TM-26] 779
LOCK-UP ECMV SOLENOID SYSTEM SHORTED 779
ACTION CODE [TM-27] 780
FAN PUMP EPC SOLENOID SYSTEM SHORTED 780
ACTION CODE [TM-28] 781
FAN REVERSE SOLENOID SYSTEM SHORTED 781
ACTION CODE [TM-29] 782
SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM FAILURE 782
ACTION CODE [TM-30] 783
TRAVEL DAMPENER SOLENOID SHORTED OR OPEN 783
TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (WRK MODE) 785
CONNECTOR TYPES AND INSTALLATION POSITIONS 789
CONNECTOR LAYOUT DRAWING 796
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 802
ERROR CODE [D193KA] 805
JOYSTICK STEERING CONTROL SYSTEM OPEN 805
ERROR CODE [D193KB] 807
JOYSTICK STEERING CONTROL SYSTEM SHORTED 807
ERROR CODE [DB90KK] 809
POWER SUPPLY TO WORK EQUIPMENT CONTROLLER IS LOW 809
ERROR CODE [DB92KK] 811
CONTROLLER POWER TO THE SOLENOID SYSTEM IS LOW 811
ERROR CODE [DB95KX] 813
DEFECTIVE 5 VOLT POWER SUPPLY 813
ERROR CODE [DD1ALD] 816
SHORT OR OPEN IN REMOTE POSITIONER UP SET SWITCH 816
ERROR CODE [DD1BLD] 818
SHORT OR OPEN IN REMOTE POSITIONER “DWN” SET SWITCH 818
ERROR CODE [DFAOKM] 820
DEFECTIVE NEUTRAL CAUTION FOR JOYSTICK WORK EQUIPMENT 820
ERROR CODE [DK59KA] 822
DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER 822
ERROR CODE [DK59KY] 824
DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER 824
ERROR CODE [DK59L8] 826
DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER 826
ERROR CODE [DK5AKA] 828
DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER 828
ERROR CODE [DK5AKY] 830
DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER 830
ERROR CODE [DK5BKA] 832
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER 832
ERROR CODE [DK5BKY] 834
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER 834
ERROR CODE [DK5BL8] 836
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER 836
ERROR CODE [DK5CKA] 838
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER 838
ERROR CODE [DK5CKY] 840
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER 840
ERROR CODE [DK5DKA] 842
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER 842
ERROR CODE [DK5DKY] 844
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER 844
ERROR CODE [DK5DL8] 846
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER 846
ERROR CODE [DK5EKA] 848
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER 848
ERROR CODE [DK5EKY] 850
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER 850
ERROR CODE [DK5FKA] 852
OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER 852
ERROR CODE [DK5FKY] 854
OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER 854
ERROR CODE [DK5FKM] 856
JOYSTICK STEERING EPC LEVER NEUTRAL SYSTEM 856
ERROR CODE [DK5FL8] 857
OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER 857
ERROR CODE [DK5GKA] 859
OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER 859
ERROR CODE [DK5GKY] 861
OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER 861
ERROR CODE [DKAOKA] 863
OPEN OR SHORT IN LIFT ARM ANGLE SENSOR SYSTEM 863
ERROR CODE [DKAOKY] 865
OPEN OR SHORT IN LIFT ARM ANGLE SENSOR SYSTEM 865
ERROR CODE [DLE2LC] 867
DEFECTIVE ENGINE SPEED SENSOR SYSTEM 867
ERROR CODE [DLT3LC] 868
DEFECTIVE ENGINE SPEED SENSOR SYSTEM 868
ERROR CODE [DUM1KB] 869
REMOTE POSITIONER “RAISE” LAMP SYSTEM FAULT 869
ERROR CODE [DUM2KB] 871
REMOTE POSITIONER “LOWER” LAMP SYSTEM FAULT 871
ERROR CODE [DW4PKA] 873
OPEN IN LIFT ARM “RAISE” EPC SOLENOID SYSTEM 873
ERROR CODE [DW4PKB] 874
SHORT IN LIFT ARM “RAISE” EPC SOLENOID SYSTEM 874
ERROR CODE [DW4QKA] 875
OPEN IN LIFT ARM “LOWER” EPC SOLENOID SYSTEM 875
ERROR CODE [DW4QKB] 876
SHORT IN LIFT ARM “LOWER” EPC SOLENOID SYSTEM 876
ERROR CODE [DW4RKA] 877
OPEN IN BUCKET “TILT” EPC SOLENOID SYSTEM 877
ERROR CODE [DW4RKB] 878
SHORT IN BUCKET “TILT” EPC SOLENOID SYSTEM 878
ERROR CODE [DW4SKA] 879
OPEN IN BUCKET “DUMP” EPC SOLENOID SYSTEM 879
ERROR CODE [DW4SKB] 880
SHORT IN BUCKET “DUMP” EPC SOLENOID SYSTEM 880
ERROR CODE [DWM1KA] 881
OPEN IN NEUTRAL LOCK EPC SOLENOID SYSTEM 881
ERROR CODE [DWM1KB] 882
SHORT IN neutral lock EPC SOLENOID SYSTEM 882
ERROR CODE [DWN6KB] 883
SHORT IN LIFT ARM “RAISE” EPC LEVER DETENT 883
ERROR CODE [DWN6KA] 885
OPEN IN LIFT ARM “RAISE” EPC LEVER DETENT 885
ERROR CODE [DWN7KA] 887
OPEN IN LIFT ARM “FLOAT” EPC LEVER DETENT 887
ERROR CODE [DWN7KB] 889
SHORT IN LIFT ARM “FLOAT” EPC LEVER DETENT 889
ERROR CODE [DWN8KA] 891
OPEN OR SHORT IN BUCKET “TILT” DETENT 891
ERROR CODE [DWN8KB] 893
OPEN OR SHORT IN BUCKET “TILT” DETENT 893
ERROR CODE [DXHJKA] 895
OPEN IN 3RD VALVE EXTENSION EPC SOLENOID SYSTEM 895
ERROR CODE [DXHJKB] 896
SHORT IN 3RD VALVE EXTENSION EPC SOLENOID SYSTEM 896
ERROR CODE [DXHKKA] 897
OPEN IN 3RD VALVE RETRACTION EPC SOLENOID SYSTEM 897
ERROR CODE [DXHKKB] 898
SHORT IN 3RD VALVE RETRACTION EPC SOLENOID SYSTEM 898
ERROR CODE [DXHLKA] 899
JOYSTICK STEERING RIGHT HAND CONTROL SYSTEM OPEN 899
ERROR CODE [DXHLKB] 901
JOYSTICK STEERING RIGHT HAND CONTROL SYSTEM SHORTED 901
ERROR CODE [DXHMKA] 903
JOYSTICK STEERING LEFT HAND CONTROL SYSTEM OPEN 903
ERROR CODE [DXHMKB] 905
JOYSTICK STEERING LEFT HAND CONTROL SYSTEM SHORTED 905
WRK-1 907
DEFECTIVE LIFT ARM LOCK SWITCH SYSTEM 907
WRK-2 908
DEFECTIVE REMOTE POSITIONER “RAISE” SWITCH 908
WRK-3 910
DEFECTIVE REMOTE POSITIONER “LOWER” SWITCH 910
WRK-4 912
DEFECTIVE REMOTE POSITIONER “RAISE” SWITCH 912
WRK-5 914
DEFECTIVE REMOTE POSITIONER “LOWER ON-OFF” SWITCH 914
WRK-6 916
DEFECTIVE BUCKET CYLINDER PROXIMITY SWITCH SYSTEM 916
WRK-7 918
OPEN OR SHORT IN BUCKET CYLINDER FULL STROKE SYSTEM 918
WRK-8 920
DEFECTIVE SEMI-AUTOMATIC DIGGING SELECTION SWITCH 920
WRK-9 922
DEFECTIVE SEMI-AUTOMATIC DIGGING SELECTION SWITCH 922
WRK-10 924
DEFECTIVE JOYSTICK ON/OFF SWITCH 924
WRK-11 926
DEFECTIVE JOYSTICK HI/LO SWITCH 926
WRK-12 928
JOYSTICK STEERING LEFT HAND CONTROL SYSTEM SHORTED 928
WRK-13 930
OPEN OR SHORT IN LIFT ARM “RAISE” EPC LEVER DETENT 930
WRK-14 932
OPEN IN LIFT ARM “FLOAT” EPC LEVER DETENT 932
WRK-15 934
OPEN OR SHORT IN BUCKET “TILT” DETENT 934
WRK-16 935
SHORT IN NEUTRAL LOCK EPC SOLENOID SYSTEM 935
WRK-17 936
SHORT IN LIFT ARM “RAISE” EPC SOLENOID SYSTEM 936
WRK-18 937
SHORT IN LIFT ARM “LOWER” EPC SOLENOID SYSTEM 937
WRK-19 938
SHORT IN BUCKET “TILT” EPC SOLENOID SYSTEM 938
WRK-20 939
SHORT IN BUCKET “DUMP” EPC SOLENOID SYSTEM 939
WRK-21 940
SHORT IN 3RD VALVE EXTENSION EPC SOLENOID SYSTEM 940
WRK-22 941
SHORT IN 3RD VALVE RETRACTION EPC SOLENOID SYSTEM 941
WRK-23 942
OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER 942
WRK-24 944
OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER 944
WRK-25 946
DEFECTIVE BUCKET POSITIONER LIFT ARM KICK-OUT FUNCTION 946
WRK-26 949
DEFECTIVE BUCKET POSITIONER LIFT ARM KICK-OUT FUNCTION 949
WRK-27 952
DEFECTIVE BUCKET LEVER FUNCTION 952
WRK-28 955
DEFECTIVE LIFT ARM FLOAT FUNCTION 955
TROUBLESHOOTING MACHINE MONITOR PANEL SYSTEM (MON MODE) 959
CONNECTOR TYPES AND INSTALLATION LOCATIONS 963
CONNECTOR LAYOUT DRAWING 970
MONITOR SYSTEM DIAGRAM 976
ERROR CODE [2F00KM] 980
DRAGGING PARKING BRAKE 980
ERROR CODE [2G42ZG] 982
ACCUMULATOR OIL PRESSURE (FRONT CIRCUIT) LOW 982
ERROR CODE [2G43ZG] 984
ACCUMULATOR OIL PRESSURE (REAR BRAKE CIRCUIT) LOW 984
ERROR CODE [AA1ANX] 986
AIR CLEANER 1 CLOGGED 986
ERROR CODE [AB00L6] 988
DEFECTIVE BATTERY CHARGING CIRCUIT (ALTERNATOR TERMINAL R SIGNAL DETECTED WHEN ENGINE STOPPED) 988
ERROR CODE [AB00MA] 990
DEFECTIVE BATTERY CHARGING CIRCUIT (NO ALTERNATOR TERMINAL R SIGNAL DETECTED, DETECTION FAILURE) 990
ERROR CODE [B@BAZG] 992
ENGINE OIL PRESSURE LOW 992
ERROR CODE [B@BAZK] 994
ENGINE OIL LEVEL LOW 994
ERROR CODE [B@BCZK] 996
ALARM INDICATING LOW COOLANT LEVEL 996
ERROR CODE [B@BCNS] 998
ENGINE COOLANT TEMPERATURE OVERHEATING 998
ERROR CODE [B@HANS] 1000
HYDRAULIC OIL TEMPERATURE OVERHEATING 1000
ERROR CODE [B@CENS] 1002
TORQUE CONVERTER OIL TEMPERATURE OVERHEATING 1002
ERROR CODE [D5ZHL6] 1004
START SWITCH C (IGN “C”) INPUT FAILURE 1004
ERROR CODE [DAF3KK] 1006
SW POWER SUPPLY (FOR OPERATION) = ON AND NSW POWER SUPPLY (FOR MEMORY) = OFF 1006
ERROR CODE [DAF5KP] 1008
5-V POWER SUPPLY OUTPUT FAILURE 1008
ERROR CODE [DAF6KP] 1010
24-V POWER SUPPLY OUTPUT FAILURE 1010
ERROR CODE [DAFBKM] 1012
WRONG INFORMATION ON MODEL SELECTION 1012
ERROR CODE [DAFSKQ] 1013
WRONG INFORMATION ON METER DISPLAY SELECTION 1013
ERROR CODE [DAQSKR] 1014
S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND TRANSMISSION CONTROLLER) 1014
ERROR CODE [DB2SKR] 1016
S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND ENGINE CONTROLLER 1016
ERROR CODE [DA80L4] 1018
AUTO GREASE INPUT FAILURE 1018
ERROR CODE [DBQSKR] 1020
S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER 1020
ERROR CODE [DD15LD] 1022
MONITOR PANEL MODE SELECTOR SWITCH 1 (PANEL SW1) INPUT ERROR 1022
ERROR CODE [DD16LD] 1024
MONITOR PANEL MODE SELECTOR SWITCH 1 (PANEL SW2) INPUT ERROR 1024
ERROR CODE [DD17LD] 1026
MONITOR PANEL MODE SELECTOR SWITCH 2 (PANEL SW3) INPUT ERROR 1026
ERROR CODE [DD18LD] 1028
MONITOR PANEL MODE SELECTOR SWITCH 2 (PANEL SW4) INPUT ERROR 1028
ERROR CODE [DD1CLD] 1030
SUB-TOTAL SWITCH FAILURE 1030
ERROR CODE [DGE2KX] 1032
ENGINE COOLANT TEMPERATURE SENSOR SYSTEM FAILURE 1032
ERROR CODE [DDK6KM] 1034
CAUTION: FNR (FORWARD-REVERSE) LEVER SWITCH IS IN N (NEUTRAL) 1034
ERROR CODE [DDS5L6] 1035
DECREASED STEERING OIL PRESSURE 1035
ERROR CODE [DDY0LD] 1037
CANCEL SWITCH FAILURE 1037
ERROR CODE [DGH2KX] 1039
HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM FAILURE 1039
ERROR CODE [DGT1KX] 1041
TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM FAILURE 1041
ERROR CODE [DHE4L6] 1043
ENGINE OIL PRESSURE SENSOR SYSTEM FAILURE 1043
ERROR CODE [DHPCKX] 1045
BOTTOM PRESSURE SENSOR FAILURE 1045
ERROR CODE [DHPDKX] 1047
HEAD PRESSURE SENSOR FAILURE 1047
ERROR CODE [DKA0KX] 1049
BOOM ANGLE SENSOR FAILURE 1049
ERROR CODE [DV00KB] 1051
SHORT-CIRCUITED ALARM BUZZER OUTPUT SYSTEM 1051
ERROR CODE [DY30ME] 1053
THE EMERGENCY STEERING REMAINS ACTUATED FOR MORE THAN ONE MINUTE 1053
ACTION CODE [MON-1] 1055
THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT UP WHEN THE PARKING BRAKE SWITCH IS TURNED ON 1055
ACTION CODE [MON-2] 1057
CIRCUIT DIAGNOSTIC PROCEDURES FOR ERROR CODE 1057
ACTION CODE [MON-3] 1059
THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (REAR C 1059
ACTION CODE [MON-4] 1061
THE AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT ON 1061
ACTION CODE [MON-5] 1063
THE ENGINE HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON 1063
ACTION CODE [MON-6] 1065
THE ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT ON 1065
ACTION CODE [MON-7] 1067
THE ENGINE COOLANT TEMPERATURE CAUTION LAMP DOES NOT LIGHT 1067
ACTION CODE [MON-8] 1069
THE RADIATOR COOLANT VOLUME CAUTION LAMP DOES NOT LIGHT ON 1069
ACTION CODE [MON-9] 1071
THE HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT 1071
ACTION CODE [MON-10] 1073
THE TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON 1073
ACTION CODE [MON-11] 1075
THE STEERING HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON 1075
ACTION CODE [MON-12] 1077
INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW1) 1077
ACTION CODE [MON-13] 1079
INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW2) 1079
ACTION CODE [MON-14] 1081
INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW3) 1081
ACTION CODE [MON-15] 1083
INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW4) 1083
ACTION CODE [MON-16] 1085
DEFECTIVE SUBTOTAL SWITCH 1085
ACTION CODE [MON-17] 1087
DEFECTIVE CANCEL SWITCH 1087
ACTION CODE [MON-18] 1089
DEFECTIVE BOTTOM PRESSURE SENSOR (SHORT FAULT) 1089
ACTION CODE [MON-19] 1091
DEFECTIVE HEAD SENSOR 1091
ACTION CODE [MON-20] 1093
THE ALARM BUZZER DOES NOT SOUND OR STOP 1093
TROUBLESHOOTING OF CHASSIS ELECTRICAL SYSTEM (E MODE) 1095
CONNECTOR TYPES AND INSTALLATION LOCATIONS 1096
CONNECTOR LAYOUT DRAWING 1103
ELECTRICAL SYSTEM DIAGRAM 1109
ACTION CODE: [E-1] 1111
BUCKET POSITIONER, BOOM KICK-OUT, AND FLOAT DO NOT FUNCTION 1111
ACTION CODE [E-2] 1113
BOOM KICK-OUT DOES NOT FUNCTION OR CANNOT BE RELEASED 1113
ACTION CODE: [E-3] 1115
BUCKET LEVER DOES NOT FUNCTION OR CANNOT BE RELEASED 1115
ACTION CODE: [E-4] 1117
BOOM FLOAT DOES NOT FUNCTION OR CANNOT BE CANCLED 1117
ACTION CODE: [E-5A] 1119
THE FRONT WIPER DOES NOT FUNCTION 1119
ACTION CODE: [E-5B] 1122
THE REAR WIPER DOES NOT FUNCTION 1122
ACTION CODE: [E-5C] 1124
THE SIDE WIPER DOES NOT FUNCTION 1124
ACTION CODE: [E-6] 1126
THE WINDOW WASHER DOES NOT FUNCTION 1126
ACTION CODE: [E-7A] 1128
THE HEADLAMP (LO BEAM) DOES NOT FUNCTION 1128
ACTION CODE: [E-7B] 1130
THE HEADLAMP (HI BEAM) DOES NOT FUNCTION 1130
ACTION CODE: [E-7C] 1132
CLEARANCE LAMPS DO NOT FUNCTION 1132
ACTION CODE: [E-7D] 1134
TURN SIGNAL DOES NOT FUNCTION 1134
ACTION CODE: [E-8] 1137
HORN DOES NOT SOUND 1137
CODE: [E-9] 1138
AIR CONDITIONER SYSTEM DOES NOT WORK 1138
CODE: (E-9) 1141
AIR DOES NOT FLOW FROM SYSTEM AND CANNOT BE ADJUSTED 1141
30 DISASSEMBLY AND ASSEMBLY 1145
METHOD OF USING MANUAL 1149
PRECAUTIONS WHEN CARRYING OUT OPERATION 1150
FUEL SUPPLY PUMP ASSEMBLY 1153
SPECIAL TOOLS 1153
REMOVAL 1153
INSTALLATION 1156
SCHEMATIC DRAWINGS OF SPECIAL TOOLS 1159
A1 Remover 1159
A1 Block 1159
A1 Bolt 1160
NOZZLE HOLDER ASSEMBLY 1161
REMOVAL 1161
INSTALLATION 1164
CYLINDER HEAD ASSEMBLY 1166
SPECIAL TOOL 1166
REMOVAL 1166
INSTALLATION 1173
RADIATOR ASSEMBLY 1176
REMOVAL 1176
INSTALLATION 1178
AIR AFTERCOOLER ASSEMBLY 1179
REMOVAL 1179
INSTALLATION 1179
COOLING FAN DRIVE MOTOR 1180
REMOVAL 1180
INSTALLATION 1181
ENGINE ASSEMBLY 1182
REMOVAL 1182
INSTALLATION 1188
STEERING, SWITCH, COOLING FAN PUMPS 1190
REMOVAL 1190
INSTALLATION 1191
TORQUE CONVERTER CHARGE, WORK EQUIPMENT AND PPC PUMP ASSEMBLY 1192
REMOVAL 1192
INSTALLATION 1192
TORQUE CONVERTER, TRANSMISSION ASSEMBLY 1193
REMOVAL 1193
INSTALLATION 1198
TORQUE CONVERTER ASSEMBLY (standard) 1199
SPECIAL TOOLS 1199
DISASSEMBLY 1199
ASSEMBLY 1201
TORQUE CONVERTER ASSEMBLY (lock-up) 1204
SPECIAL TOOLS 1204
DISASSEMBLY 1204
ASSEMBLY 1207
TRANSMISSION ASSEMBLY 1212
SPECIAL TOOLS 1212
DISASSEMBLY 1212
ASSEMBLY 1220
SCHEMATICS OF SPECIAL TOOLS 1230
C1 Bracket 1230
C6, C7 Pushing tools 1230
C7 Spacer 1231
C11 Lifting tool 1231
C11 Lifting tool 1232
TRANSMISSION CLUTCH PACK ASSEMBLY 1233
SPECIAL TOOLS 1233
DISASSEMBLY 1233
Disassembly of forward-reverse clutch packs 1233
Forward clutch 1233
Reverse clutch 1235
Disassembly of 1st • 4th speed clutch packs 1236
1st speed clutch 1236
4th speed clutch 1237
Disassembly of 2nd • 3rd clutch packs 1238
3rd clutch 1238
2nd speed clutch 1240
Assembly of forward-reverse clutch packs 1241
Reverse clutch 1241
Forward clutch 1243
Assembly of 1st • 4th clutch packs 1245
4th-speed clutch 1245
1st-speed clutch 1247
Assembly of 2nd • 3rd clutch packs 1249
2nd-speed clutch 1249
3rd-speed clutch 1251
SCHEMATIC DIAGRAM OF SPECIAL TOOL 1255
C2 Push tool 1255
PARKING BRAKE ASSEMBLY 1256
SPECIAL TOOLS 1256
DISASSEMBLY 1256
ASSEMBLY 1259
SCHEMATIC DRAWING OF SPECIAL TOOLS 1265
C4, C5 Push tool 1265
C5 Spacer 1265
C8 Push tool 1266
C9 Push tool 1266
C10 Push tool 1267
C13 Bracket 1267
FRONT AXLE ASSEMBLY 1268
DISASSEMBLY 1268
ASSEMBLY 1270
REAR AXLE ASSEMBLY 1271
REMOVAL 1271
INSTALLATION 1274
AXLE HOUSING ASSEMBLY 1276
SPECIAL TOOLS 1276
DISASSEMBLY 1276
ASSEMBLY 1280
SCHEMATIC DRAWING OF SPECIAL TOOLS 1286
D7 Pushing tool 1286
D7 Spacer 1286
D7 Pushing tool 1287
D9 Support 1287
D9 Support 1288
DIFFERENTIAL ASSEMBLY 1289
SPECIAL TOOLS 1289
DISASSEMBLY 1289
ASSEMBLY 1295
SCHEMATIC DRAWING OF SPECIAL TOOLS 1307
D1 Plate 1307
D2, D3 Push tool 1307
D3 Spacer 1308
D4 Push tool 1308
D5 Push tool 1309
CENTER HINGE PIN 1310
SPECIAL TOOLS 1310
REMOVAL 1310
INSTALLATION 1316
VALVE ASSEMBLY 1320
REMOVAL 1320
INSTALLATION 1320
TRAVEL DAMPER ASSEMBLY 1321
REMOVAL 1321
INSTALLATION 1321
PARKING BRAKE DISC 1322
SPECIAL TOOLS 1322
REMOVAL 1322
INSTALLATION 1324
SCHEMATIC DRAWING OF SPECIAL TOOLS 1325
C13 Bracket 1325
HYDRAULIC TANK 1326
REMOVAL 1326
INSTALLATION 1327
WORK EQUIPMENT VALVE ASSEMBLY 1328
REMOVAL 1328
INSTALLATION 1329
HYDRAULIC CYLINDER ASSEMBLY 1330
SPECIAL TOOLS 1330
DISASSEMBLY 1330
ASSEMBLY 1334
WORK EQUIPMENT ASSEMBLY 1340
REMOVAL 1340
INSTALLATION 1343
COUNTERWEIGHT 1345
REMOVAL 1345
INSTALLATION 1346
FUEL TANK ASSEMBLY 1347
REMOVAL 1347
INSTALLATION 1348
CAB ASSEMBLY 1349
REMOVAL 1349
INSTALLATION 1352
CAB, FLOOR FRAME ASSEMBLY 1353
REMOVAL 1353
INSTALLATION 1357
AIR CONDITIONER UNIT ASSEMBLY 1358
REMOVAL 1358
INSTALLATION 1361
AIR CONDITIONER COMPRESSOR ASSEMBLY 1362
SPECIAL TOOLS 1362
REMOVAL 1362
INSTALLATION 1363
90 OTHERS 0
BRAKE OIL CIRCUIT DIAGRAM 0
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 0
WITHOUT TORQUE CONVETER LOCKUP CLUTCH 0
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 0
WITH TORQUE CONVERTER LOCKUP CLUTCH 0
HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT 0
STANDARD 0
ELECTRIC CIRCUIT DIAGRAM 0
FLOOR HARNESS 0
STANDARD 0
FOR JOYSTICK 0
ENGINE HARNESS 0
ECSS AND LOAD METER SUPPLEMENT 1380
COVER 1380
CONTENTS 1381
ECSS VALVE (OP) 1382
MACHINE MONITOR 1384
LOAD METER FUNCTION (OP) 1384
AMP070-20 [CN-L51] 1393
AMP070-12P [CN-L57] 1395
TRANSMISSION CONTROLLER 1397
INPUT AND OUTPUT SIGNALS 1398
TESTING AND ADJUSTING LOAD METER 1399
TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM 1403
CONNECTOR TYPES AND INSTALLATION POSITIONS 1403
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 1411
H-30 ECSS DOES NOT WORK, AND THERE IS PITCHING AND BOUNCING 1411

S.V 15/12/24