Komatsu WA380-5L Wheel Loader Shop Manual CEBM009703 PDF

Description

Komatsu WA380-5L Wheel Loader Shop Manual CEBM009703 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA380-5L Wheel Loader Shop Manual CEBM009703 – PDF DOWNLOAD 

Language : English
Pages : 1488
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu WA380-5L Wheel Loader Shop Manual CEBM009703 – PDF DOWNLOAD 

SERIAL NUMBERS WA380-5L A52001 and UP

GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards when inspecting disassembled parts.
STANDARD VALUE TABLE
This section explains the standard values for new machine and judgement criteria for testing, adjusting and
troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts
in troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs.
TROUBLESHOOTING
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
DIAGRAMS AND SCHEMATICS
This section has the foldout drawings for the machine.

TABLE OF CONTENTS:

Komatsu WA380-5L Wheel Loader Shop Manual CEBM009703 – PDF DOWNLOAD

SERIAL NUMBERS WA380-5L A52001 and UP

COVER 1
FOREWORD 2
CONTENTS 2
SAFETY 21
SAFETY NOTICE 21
IMPORTANT SAFETY NOTICE 21
GENERAL PRECAUTIONS 21
PREPARATIONS FOR WORK 21
PRECAUTIONS DURING WORK 21
GENERAL 23
HOW TO READ THE SHOP MANUAL 24
VOLUMES 24
DISTRIBUTION AND UPDATING 24
FILING METHOD 24
REVISED EDITION MARK 24
REVISIONS 24
SYMBOLS 24
HOISTING INSTRUCTIONS 25
HOISTING 25
WIRE ROPES 25
PUSH PULL COUPLER 26
TYPE 1 26
DISCONNECTION 26
CONNECTION 26
TYPE 2 27
DISCONNECTION 27
CONNECTION 27
TYPE 3 28
DISCONNECTION 28
CONNECTION 28
COATING MATERIALS 29
STANDARD TIGHTENING TORQUE 31
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 31
TIGHTENING TORQUE OF HOSE NUTS 32
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 32
TIGHTENING TORQUE FOR FLARED NUTS 32
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS 33
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS 33
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) 33
ELECTRIC WIRE CODE 34
CLASSIFICATION BY THICKNESS 34
CLASSIFICATION BY COLOR AND CODE 34
CONVERSION TABLES 35
METHOD OF USING THE CONVERSION TABLE 35
01 GENERAL 41
SPECIFICATIONS 42
WEIGHT TABLE 46
FUEL, COOLANT AND LUBRICANTS 48
GENERAL ASSEMBLY DRAWING 51
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 53
COOLING SYSTEM 59
Specifications 59
ENGINE MOUNT, TRANSMISSION MOUNT 60
POWER TRAIN 61
POWER TRAIN SYSTEM DIAGRAM 62
Without Torque Converter Lockup Clutch 62
With Torque Converter Lock-up Clutch 63
Outline 64
DRIVE SHAFT (PROPELLER SHAFT) 65
Outline 65
TORQUE CONVERTER, TRANSMISSION PIPING 66
TORQUE CONVERTER 67
Without Lock-up Clutch 67
Path Of Power Transmission 69
Power Flow 69
Oil Flow 69
With Lock-up Clutch 70
Path Of Power Transmission 74
Lock-up Clutch Disengaged 74
Lock-up Clutch Engaged 74
Oil Flow 75
TRANSMISSION 76
Outline 82
F and R Clutches: Without Lock-up Clutch 83
F and R Clutches: With Lock-up Clutch 84
1st and 4th Clutch 85
2nd and 3rd Clutch 86
Clutch Operation 87
Clutch Engaged 87
Clutch Disengaged 87
Forward 1st 88
Operation 88
Forward 2nd 89
Operation 89
Forward 3rd 90
Operation 90
Forward 4th 91
Operation 91
Reverse 1st 92
Operation 92
TRANSMISSION CONTROL VALVE 93
Without Lock-up Clutch (Transmission S/N 110643) 93
Without Lock-up Clutch (Transmission S/N 110644 and up) 94
With Lock-up Clutch (Transmission S/N 110643) 96
With Lock-up Clutch (Transmission S/N 110644 and up) 97
Electronic Control Modulation Valve (ECMV) 99
ECMV for Speed Clutch 100
Outline of ECMV 100
ECMV and Proportional Solenoid 100
ECMV and Fill Switch 101
ECMV Actuation 101
ECMV for Lock-up Clutch 102
Outline 102
Operation 103
Main Relief, Torque Converter Relief Valve 104
Outline 105
Operation 105
Flow Valve 107
Operation 107
AXLE 108
Front Axle 108
Rear Axle 109
DIFFERENTIAL 110
Front Differential 110
Rear Differential 112
Outline 114
Limited Slip Differential 115
Operation of Limited Slip Differential 117
FINAL DRIVE 120
Outline 122
AXLE MOUNTING, CENTER HINGE PIN 124
Outline 124
STEERING PIPING 128
STEERING COLUMN, ORBIT ROLL 129
STEERING VALVE 130
Overload Relief Valve 132
Function 132
Operation 132
Steering Relief Valve 133
Function 133
Steering Relief Valve Operation 134
Demand Valve Operation 135
Flow amp 138
Steering Valve Operation 141
Neutral 141
Turning Right 142
Turning Left 143
ORBIT-ROLL VALVE 144
Outline 145
Structure 145
Connection Between the Hand Pump and Sleeve 146
Function of Center Spring 147
STOP VALVE 148
STEERING PUMP, SWITCH PUMP 150
Outline 151
EMERGENCY STEERING PUMP 152
Function 153
EMERGENCY STEERING MOTOR 154
Function 154
STEERING CYLINDER 156
JOYSTICK STEERING 158
Joystick PPC Valve 159
Function 159
Steering Switch Valve 161
Operation 161
BRAKE PIPING 162
BRAKE VALVE 164
Brake Valve – Left 164
Brake Valve – Right 166
Outline 167
Operation 168
CHARGE VALVE 172
Function 173
Operation 174
PPC RELIEF VALVE 176
Outline 176
Operation 176
ACCUMULATOR – BRAKE 178
Function 178
Specifications 178
Function 179
Specifications 179
BRAKE 180
Front 180
Outline 181
Rear 182
Outline 183
Operation 184
PARKING BRAKE CONTROL 185
Outline 185
PARKING BRAKE 186
OUTLINE 186
Parking Brake Solenoid Valve 188
Operation 189
Parking Brake Emergency Release Valve 189
Outline 189
HYDRAULIC PIPING 190
Outline 192
WORK EQUIPMENT CONTROL LEVER 194
For PPC Valve 194
For EPC Valve (If Equipped) 195
HYDRAULIC TANK 196
Breather 197
TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PILOT CONTROL PUMPS 198
PPC RELIEF VALVE 200
Outline 200
Operation 200
E C S S VALVE (If Equipped) 202
WORK EQUIPMENT CONTROL VALVE 205
2-Spool Valve 205
3-Spool Valve 209
Relief Valve 212
Function 212
Operation 212
Safety-suction Valve 213
Function 213
Operation 213
Suction Valve 214
Function 214
Operation 214
Cut-off Valve 215
Function 215
Operation 215
Work Equipment Control Valve Operation 217
NEUTRAL Position of Lift Arm and Bucket Spools 217
RAISE Position for Lift Arm Spool 218
LOWER Position of Lift Arm Spool 219
FLOAT Position of Lift Arm Spool 220
DUMP Position for Bucket Spool 221
TILT Position for Bucket Spool 222
WORK EQUIPMENT PPC VALVE 224
Operation 226
PPC VALVE (FOR MULTI FUNCTION MONO LEVER) 230
Operation 232
EPC SOLENOID VALVE (If equipped) 235
Function 236
Operation 236
SHUT OFF VALVE (If equipped) 238
Function 238
ATTACHMENT PPC VALVE (If equipped) 240
Operation 242
COOLING FAN MOTOR 244
Model: LMF28 244
Hydraulic Motor 246
Suction Valve 247
Operation of Revolution Direction Changeover Valve 248
COOLING FAN MOTOR DRIVE PUMP 250
Model: LPV 250
Servo Valve 256
Safety Valve 258
WORK EQUIPMENT LINKAGE 260
BUCKET 262
BUCKET POSITIONER, BOOM KICK-OUT 263
Bucket Positioner 264
Boom Kick-out 264
Proximity Switch Operation 265
When Lift Arm Is Raised 265
When Bucket Is Tilted 267
WORK EQUIPMENT CYLINDER 270
Lift Arm Cylinder 270
Bucket Cylinder 270
CAB 272
AIR CONDITIONER 273
Air Conditioner Piping 273
MACHINE MONITORING SYSTEM 274
Outline 274
Individual Circuit Diagrams of the Machine Monitor 276
Starting and Lighting Functions 276
Load Meter 276
Sensing Functions 277
Power Supply and Network 278
Automatic Preheating Function 279
MACHINE MONITOR 282
Speedometer Specifications 282
Load Meter Specification (If Equipped) 283
Table of Monitor Indication Items 284
Setting the Machine Monitor 291
Service Mode Functions 294
Items Related To The Fault History Of Electric System 298
Items Related to the Fault History Of Machine System 300
Items Related to Maintenance Monitor 302
Real-Time Monitoring Function 304
Real-Time Monitoring Items 306
Load Meter Function (If equipped) 316
Machine Setting 326
Setting Necessary For Option Mounting 327
Optional Device Setting For Machine Monitor 328
Adjustment for Each EPC 336
TRANSMISSION CONTROL SYSTEM 354
System Diagram 354
Control Function 355
Electric Circuit Diagram (Standard) 378
Electric Circuit Diagram (If Equipped) 380
TRANSMISSION CONTROLLER 382
WORK EQUIPMENT CONTROL SYSTEM 384
System Diagram 384
Electric Circuit Diagram 398
WORK EQUIPMENT CONTROLLER 400
ELECTRIC TRANSMISSION CONTROL 402
Functions 403
Combination Switch 404
Overview 404
Functions 404
Operation 405
KICK DOWN, HOLD SWITCH 406
Functions 406
ENGINE STARTING CIRCUIT 407
Function 407
Operation 408
ENGINE STOP CIRCUIT 409
OPERATION 409
PREHEATING CIRCUIT 410
Outline 410
Operation 410
ENGINE POWER MODE SELECTOR CIRCUIT 411
Function 411
Operation 411
PARKING BRAKE CIRCUIT 412
Operation 412
SENSORS 416
Engine Speed Sensor 416
Engine Oil Pressure Sensor 417
Engine Oil Level Sensor 417
Temperature Sensor 418
Coolant Temperature – For Monitor 418
Torque Converter Oil Temperature 418
Hydraulic Oil Temperature 418
Transmission Oil Temperature 418
Brake Oil Temperature 418
Coolant Temperature – Preheating 418
Transmission Cut-off Pressure Sensor 419
Coolant Level Sensor 420
Fuel Level Sensor 421
Lift Arm Angle Sensor (If Equipped) 422
Air Cleaner Clogging Sensor 423
Load Meter Pressure Sensor (If Equipped) 423
Battery Electrolyte Level Sensor(If Equipped) 424
Relay 425
20 STANDARD VALUE TABLES 427
STANDARD SERVICE VALUE TABLE 428
Standard Service Value Table For Engine 428
Standard Value Table For Chassis 429
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 440
Special Tool Drawing 442
30 TESTING AND ADJUSTING 437
ENGINE COMPONENTS 443
Determining a Defective Cylinder 443
Procedures 443
Determining Cylinder Group 443
Isolating the Defective Cylinder 443
Measuring Engine Speed 444
Measuring Exhaust Temperature 446
Measuring Exhaust Smoke 448
Adjusting Valve Clearance 449
Measuring Compression Pressure 451
Measuring Blow-by Pressure 453
Measuring Engine Oil Pressure 454
Measuring Intake Air Pressure (Boost Pressure) 455
Testing And Adjusting Fuel Injection Timing 456
Adjusting Engine Speed Sensor 457
Bleeding Air From Fuel Circuit 458
Adjusting Engine Stop Solenoid 459
ADJUSTING ACCELERATOR PEDAL 460
Adjusting the Power Mode 460
Adjusting the Normal Mode 461
ADJUSTING TRANSMISSION SPEED SENSOR 462
POWER TRAIN OIL PRESSURE 463
FLUSHING TORQUE CONVERTER, TRANSMISSION AND HYDRAULIC CIRCUIT 467
TRANSMISSION VALVE FAILS 468
MOVING MACHINE 468
STEERING CONTROL 470
STEERING OIL PRESSURE 471
TESTING HYDRAULIC FAN 473
BRAKE SYSTEM 474
Measuring Brake Oil Pressure 474
Testing Wear of Wheel Brake Disc 476
Bleeding Air from Brake Circuit 477
Testing Wear of Parking Brake Disc 478
Manual Release Method for Parking Brake 479
ACCUMULATOR CHARGE PRESSURE 480
PPC OIL PRESSURE 482
WORK EQUIPMENT HYDRAULIC PRESSURE 485
BUCKET POSITIONER 487
BOOM KICK-OUT 488
PROXIMITY SWITCH ACTUATION 489
ADJUSTING MACHINE MONITOR 490
LOAD METER 493
BLEEDING AIR 497
Fan Motor Circuit 497
Work Equipment PPC Circuit 497
Cylinders 497
RELEASING REMAINING PRESSURE 498
In Hydraulic Circuit 498
E C S S Damper Circuit 499
PM-CLINIC INSPECTION TABLE 500
40 TROUBLESHOOTING 503
POINTS TO REMEMBER WHEN TROUBLESHOOTING 517
SEQUENCE OF EVENTS IN TROUBLESHOOTING 519
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 520
Precautions When Handling Electrical Equipment 520
Handling Electronic Control Unit 524
When Troubleshooting Electrical Circuits 526
ELECTRIC WIRE CODE 527
Classification by Thickness 527
Classification by Color and Code 527
How to Read Electric Wire Code 528
Points to Remember When Handling Hydraulic Equipment 530
CHECKS BEFORE TROUBLESHOOTING 532
2 Check for impurities in fuel 532
3 Check hydraulic oil level 532
4 Check hydraulic strainer 532
5 Check swing machinery oil level 532
6 Check engine oil level 532
7 Check coolant level 532
8 Check dust indicator for clogging 532
9 Check hydraulic filter 532
10 Check final drive oil level 532
11 Check for looseness, corrosion of battery terminal, wiring 532
12 Check for looseness, corrosion of alternator terminal, wiring 532
13 Check for looseness, corrosion of starting motor terminal, wiring 532
14 Check operation of instruments 532
15 Check for abnormal noise, smell 532
16 Check for oil leakage 532
17 Carry out air bleeding 532
18 Check battery voltage (Engine stopped) 532
19 Check battery electrolyte level 532
20 Check for discolored, burnt, exposed wiring 532
21 Check for missing wiring clamps, hanging wire 532
22 Check for water leaking on wiring (Pay particular attention to water leaking on connectors or terminals) 532
23 Check for blown, corroded fuses 532
24 Check alternator voltage (Engine running at 1/2 throttle or above) 532
25 Sound of actuation of battery relay (When starting switch is turned ON, OFF) 532
SPECIAL FUNCTIONS OF MACHINE MONITOR 533
Flow of Modes and Functions 534
Failure Code Table 542
Monitoring Code Table 555
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 567
T-ADAPTER TABLE 590
CONNECTOR TYPES AND LOCATIONS 593
CONNECTOR LAYOUT DRAWING 600
TRANSMISSION CONTROL SYSTEM DIAGRAM 606
TRANSMISSION CONTROL SYSTEM (TM MODE) 609
Failure Code [1500L1] 609
Double Engagement Detected 609
Failure Code [15SAL1] 610
Short Circuit in F_ECM Fill Switch System 610
Failure Code [15SALH] 612
F_ECM Fill Switch System Disconnected 612
Failure Code [15SBL1] 614
Short Circuit in R_ECM Fill Switch System 614
Failure Code [15SBLH] 616
R_ECM Fill Switch System Disconnected 616
Failure Code [15SEL1] 618
Short Circuit in 1st_ECM Fill Switch System 618
Failure Code [15SELH] 620
1st_ECM Fill Switch System Disconnected 620
Failure Code [15SFL1] 622
Short Circuit in 2nd_ECM Fill Switch System 622
Failure Code [15SFLH] 624
2nd_ECM Fill Switch System Disconnected 624
Failure Code [15SGL1] 626
Short Circuit in 3rd_ECM Fill Switch System 626
Failure Code [15SGLH] 628
3rd_ECM Fill Switch System Disconnected 628
Failure Code [15SHL1] 630
Short Circuit in 4th_ECM Fill Switch System 630
Failure Code [15SHLH] 632
4th_ECM Fill Switch System Disconnected 632
Failure Code [15SJL1] 634
Short Circuit in Lock-up_ECM Fill Switch System 634
Failure Code [15SJLH] 635
Lock-up_ECM Fill Switch System Disconnected 635
Failure Code [989F00] 636
Transmission Protection Caution 636
Failure Code [B@C7NS] 637
Rear Brake Cooling Oil Overheat 637
Failure Code [D150KA] 638
Emergency Steering Relay Output System Disconnected 638
Failure Code [D150KB] 639
Short Circuit in Emergency Steering Relay Output System 639
Failure Code [D160KA] 640
Back-up Alarm Relay Output System Disconnected 640
Failure Code [D160KB] 641
Short Circuit in Back-up Alarm Relay Output System 641
Failure Code [D191KA] 642
Neutral Safety Relay Output System Disconnected 642
Failure Code [D191KB] 644
Short Circuit in Neutral Safety Relay Output System 644
Failure Code [D192KA] 646
E C S S Relay Output System Disconnected 646
Failure Code [D192KB] 647
Short Circuit in E C S S Relay Output System 647
Failure Code [D198KB] 648
Ground Fault in the Low Temperature By-pass Relay System 648
Failure Code [D198KY] 650
Hot-short in the Low-temperature By-pass Relay System 650
Failure Code [DAQ0KK] 652
Controller Power Supply Voltage Lowered 652
Failure Code [DAQ2KK] 654
Defective Solenoid Power Supply System 654
Failure Code [DAQ9KQ] 656
Model Selection Signal Mismatch 656
Failure Code [DDK3KA] 658
No Right FNR Switch Signal Input 658
Failure Code [DDK3KB] 660
Multiple Right FNR Switch Signal Input 660
Failure Code [DDK4KA] 662
No Input Signal to Joystick Forward/Reverse Switch 662
Failure Code [DDK4KB] 664
Multiple Joystick Forward/Reverse Switch Signals are Input 664
Failure Code [DDK5LD] 666
Hot Short in Joystick Shift_Up/Shift_Down Switch 666
Failure Code [DDK6KA] 668
No Input Signal from Forward-Reverse Lever 668
Failure Code [DDK6KB] 670
Multiple Forward-Reverse Lever Signal Input 670
Failure Code [DDS5KA] 672
Steering Pressure Switch Open 672
Failure Code [DDS5KB] 674
Steering Pressure Switch Grounded 674
Failure Code [DDT0L4] 676
Manual/Auto-Shift Selector Switch Selection Failure 676
Failure Code [DDT4LD] 678
Ground Fault in Transmission Cut-off Switch 678
Failure Code [DDW9LD] 680
Short in Kickdown Switch System 680
Failure Code [DDWLLD] 682
Ground Fault in Hold Switch System 682
Failure Code [DF10KA] 684
No Input Signal in Gear Shift Lever 684
Failure Code [DF10KB] 686
Multiple Gear Shift Lever Signals 686
Failure Code [DGF1KX] 688
Transmission Oil Temperature Sensor System Failure 688
Failure Code [DGR2KA] 690
Rear Brake Oil Temperature Sensor System Open 690
Failure Code [DGR2KB] 692
Ground Fault In Rear Brake Oil Temperature Sensor System 692
Failure Code [DHT1KX] 694
Transmission Cut-off (Left Brake Pressure Sensor) Signal Open 694
Failure Code [DLE2KA] 696
Engine Speed Sensor Open 696
Failure Code [DLE2LC] 697
Engine Speed Sensor Shorted 697
Failure Code [DLT3KA] 698
Speed Sensor System Open 698
Failure Code [DT20KB] 699
Ground Fault In Indicator Lamp System (Transmission Cut-off Switch) 699
Failure Code [DW7BKA] 700
Fan Pump Reverse Solenoid System Open 700
Failure Code [DW7BKB] 701
Fan Reverse Solenoid System Shorted 701
Failure Code [DW7CKA] 702
Switch Pump Cut-off Relay Open 702
Failure Code [DW7CKB] 703
Switch Pump Cut-off Relay Ground Fault 703
Failure Code [DX16KA] 704
Fan Pump EPC Solenoid System Open 704
Failure Code [DX16KB] 705
Fan Pump EPC Solenoid System Ground Fault 705
Failure Code [DXH1KA] 706
Lock-up Clutch_ECMV Solenoid System Open 706
Failure Code [DXH1KB] 707
Lock-up Clutch ECMV Solenoid System Shorted 707
Failure Code [DXH4KA] 708
1st_ECMV Solenoid System Open 708
Failure Code [DXH4KB] 709
1st_ECMV Solenoid System Shorted 709
Failure Code [DXH5KA] 710
2nd_ECMV Solenoid System Open 710
Failure Code [DXH5KB] 711
2nd_ECMV Solenoid System Shorted 711
Failure Code [DXH6KA] 712
3rd_ECMV Solenoid System Open 712
Failure Code [DXH6KB] 713
3rd_ECMV Solenoid System Shorted 713
Failure Code [DXH7KA] 714
R_ECMV Solenoid System Open 714
Failure Code [DXH7KB] 715
R_ECMV Solenoid System Shorted 715
Failure Code [DXH8KA] 716
F_ECMV Solenoid System Open 716
Failure Code [DXH8KB] 717
F_ECMV Solenoid System Ground Fault 717
Failure Code [DXHHKA] 718
4th_ECMV Solenoid System Open 718
Failure Code [DXHHKB] 719
4th_ECMV Solenoid System Shorted 719
Failure Code [DY30MA] 720
Motor-Driven Emergency Steering Pump Failure 720
Failure Code [DY30MC] 722
Motor-Driven Emergency Steering Pump Failure 722
Failure Code [TM-1] 724
Open or Short in Kickdown Switch System 724
Failure Code [TM-2] 726
Hold Switch System Open Or Short 726
Failure Code [TM-3] 728
Torque Converter Lock-up Switch System Failure 728
Failure Code [TM-4] 730
Neutral Signal System Failure 730
Failure Code [TM-5] 732
Emergency Steering Switch Signal System Failure 732
Failure Code [TM-6] 734
Transmission Cut-off Switch System Open or Shorted 734
Failure Code [TM-7] 736
Transmission Cut-off Setting Switch System Open or Shorted 736
Failure Code [TM-8] 738
Transmission Cut-off (Left Brake Sensor) Signal Shorted 738
Failure Code [TM-9A] 740
Joystick Shift Up/shift Down Switch System Failure 740
Failure Code [TM-9B] 742
Joystick Shift Up/shift Down Switch System Failure 742
Failure Code [TM-10] 744
FNR Switch Mode Change Over Switch System Failure 744
Failure Code [TM-11] 746
Starting Switch “C” (IGN_C) Signal System Failure 746
Failure Code [TM-12] 750
Engine Power Mode Switch Open or Shorted 750
Failure Code [TM-13] 752
Open or Short in Travel Damper ON/OFF Switch 752
Failure Code [TM-14] 754
Open or Short in Hydraulic Fan Reverse Signal System 754
Failure Code [TM-15] 756
Short in Motor Driven Emergency Steering Relay System 756
Failure Code [TM-16] 757
Short in Travel Damper Relay System 757
Failure Code [TM-17] 758
Switch Pump Cut-off Relay System Shorted 758
Failure Code [TM-18] 759
Back Lamp Relay System Shorted 759
Failure Code [TM-19] 760
Neutral System Shorted 760
Failure Code [TM-20] 761
F_ECMV Solenoid System Shorted 761
Failure Code [TM-21] 762
R_ECMV Solenoid System Shorted 762
Failure Code [TM-22] 763
1st_ECMV Solenoid System Shorted 763
Failure Code [TM-23] 764
2nd_ECMV Solenoid System Shorted 764
Failure Code [TM-24] 765
3rd_ECMV Solenoid System Shorted 765
Failure Code [TM-25] 766
4th_ECMV Solenoid System Shorted 766
Failure Code [TM-26] 767
Lock-Up ECMV Solenoid System Shorted 767
Failure Code [TM-27] 768
Fan Pump EPC Solenoid System Shorted 768
Failure Code [TM-28] 769
Fan Reverse Solenoid System Shorted 769
Failure Code [TM-29] 770
Speed Sensor System Failure 770
Failure Code [TM-30] 772
E C S S Solenoid System 772
WORK EQUIPMENT CONTROL SYSTEM (WRK MODE) 774
Connector Types And Locations 774
Connector Layout Drawing 782
Work Equipment Control System Diagram 788
Failure Code [D193KA] 792
Defective Joystick Steering Relay System 792
Failure Code [D193KB] 794
The Joystick Solenoid Relay Output System Shorted 794
Failure Code [DB90KK] 796
Lowering Work Equipment Controller Power Supply Fault 796
Failure Code [DB92KK] 798
Defective Solenoid Power Supply 798
Failure Code [DB95KX] 800
Open in 5 V Power Supply 800
Failure Code [DD1ALD] 802
Defective Remote Positioner UP Set Switch 802
Failure Code [DD1BLD] 804
Defective Remote Positioner DOWN Set Switch 804
Failure Code [DFAOKM] 806
Defective Neutral Caution for Joystick Work Equipment 806
Failure Code [DK59KA] 808
Defective Lift Arm EPC Lever Potentiometer System (Main Circuit Discontinuity or Ground Fault) 808
Failure Code [DK59KY] 810
Defective Lift Arm EPC Lever Potentiometer System (Main Short Circuit) 810
Failure Code [DK59L8] 812
Defective Lift Arm EPC Potentiometer System (Displacement of Main and Sub Circuit) 812
Failure Code [DK5AKA] 814
Defective Lift Arm EPC Lever Potentiometer System (Disconnection of Main) 814
Failure Code [DK5AKY] 816
Defective Lift Arm EPC Lever Potentiometer System (Short Sub Circuit) 816
Failure Code [DK5BKA] 817
Defective Bucket EPC Lever Potentiometer System (Disconnection of Main) 817
Failure Code [DK5BKY] 818
Defective Bucket EPC Lever Potentiometer System (Main Short Circuit) 818
Failure Code [DK5BL8] 820
Defective Bucket EPC Potentiometer System (Displacement of Main and Sub Circuit) 820
Failure Code [DK5CKA] 822
Defective Bucket EPC Lever Potentiometer System (Disconnection of Main) 822
Failure Code [DK5CKY] 823
Defective Bucket EPC Lever Potentiometer System (Short Sub Circuit) 823
Failure Code [DK5DKA] 824
Defective 3rd Valve Lever Potentiometer System (Main Circuit Discontinuity or Ground Fault) 824
Failure Code [DK5DKY] 826
Defective Lift Arm EPC Lever Potentiometer System (Main Circuit Short Circuit) 826
Failure Code [DK5DL8] 828
Defective 3rd Valve EPC Potentiometer System (Displacement of Main and Sub Circuit) 828
Failure Code [DK5EKA] 830
Defective 3rd Valve Lever EPC Potentiometer System (Sub Circuit Discontinuity or Ground Fault) 830
Failure Code [DK5EKY] 831
Defective Lift Arm EPC Lever Potentiometer System (Short Sub Circuit) 831
Failure Code [DK5FKA] 832
Defective Joystick Steering EPC System (Main Circuit Open or Shorted) 832
Failure Code [DK5FKY] 833
Defective Joystick Steering EPC Potentiometer System (Main Circuit Shorted) 833
Failure Code [DK5FKM] 834
Joystick Steering EPC Lever Neutral System Caution 834
Failure Code [DK5FL8] 836
Defective Joystick Steering EPC Lever Potentiometer Input Signal 836
Failure Code [DK5GKA] 838
Defective Joystick Steering EPC Potentiometer System (Open or Short in Sub Circuit) 838
Failure Code [DK5GKY] 839
Defective Joystick Steering EPC Potentiometer System (Sub Circuit Short) 839
Failure Code [DKAOKA] 840
Defective Lift Arm Angle Sensor System (Open or Short) 840
Failure Code [DKAOKY] 842
Defective Lift Arm Angle Sensor (System Shorted) 842
Failure Code [DLE2LC] 844
Defective Engine Speed Sensor System 844
Failure Code [DLT3LC] 845
Defective Transmission Output AXIS Speed Sensor System (Open) 845
Failure Code: [DUM1KB] 846
Remote Positioner RAISE Lamp System Ground Fault 846
Failure Code: [DUM2KB] 847
Remote Positioner LOWER Lamp System Ground Fault 847
Failure Code: [DW4PKA] 848
Disconnected Lift Arm RAISE EPC Solenoid System 848
Failure Code: [DW4PKB] 849
Lift Arm RAISE EPC Solenoid System Ground Fault 849
Failure Code: [DW4QKA] 850
Disconnected Lift Arm LOWER EPC Solenoid System 850
Failure Code: [DW4QKB] 851
Lift Arm LOWER EPC Solenoid System Ground Fault 851
Failure Code: [DW4RKA] 852
Disconnected Bucket TILT EPC Solenoid System 852
Failure Code: [DW4RKB] 853
Bucket TILT EPC Solenoid System Ground Fault 853
Failure Code: [DW4SKA] 854
Disconnected Bucket DUMP EPC Solenoid System 854
Failure Code: [DW4SKB] 855
Bucket DUMP EPC Solenoid System Ground Fault 855
Failure Code: [DWM1KA] 856
Work Equipment Neutral Lock Solenoid System Disconnection 856
Failure Code: [DWM1KB] 857
Work Equipment Neutral Lock Solenoid System Ground Fault 857
Failure Code: [DWN6KA] 858
Lift Arm RAISE Magnet Detent System Disconnection 858
Failure Code: [DWN6KB] 860
Lift Arm RAISE Magnet Detent System Ground Fault 860
Failure Code: [DWN7KA] 862
Lift Arm FLOATING Magnet Detent System Disconnection 862
Failure Code: [DWN7KB] 864
Lift Arm FLOATING Magnet Detent System Ground Fault 864
Failure Code: [DWN8KA] 866
Lift Arm TILT Magnet Detent System Disconnection 866
Failure Code: [DWN8KB] 867
Lift Arm TILT Magnet Detent System Ground Fault 867
Failure Code: [DXHJKA] 868
3rd Valve Extension EPC Solenoid System Disconnection 868
Failure Code: [DXHJKB] 869
3rd Valve Extension EPC Solenoid System Ground Fault 869
Failure Code: [DXHKKA] 870
3rd Valve Retraction EPC Solenoid System Disconnection 870
Failure Code: [DXHKKB] 871
3rd Valve Retraction EPC Solenoid System Ground Fault 871
Failure Code: [DXHLKA] 872
Open in Joystick Steering Right-Hand EPC Solenoid System 872
Failure Code: [DXHLKB] 874
Joystick Steering Right-Hand EPC Solenoid System Ground Fault 874
Failure Code: [DXHMKA] 876
Joystick Steering Left-Hand EPC Solenoid System Open 876
Failure Code: [DXHMKB] 878
Joystick Steering Left-Hand EPC Solenoid System Ground Fault 878
Failure Code: [WRK-1] 880
Defective Lift Arm Lock Switch System 880
Failure Code: [WRK-2] 882
Defective Remote Positioner RAISE Setting Switch System 882
Failure Code: [WRK-3] 884
Defective Remote Positioner LOWER Setting Switch System 884
Failure Code: [WRK-4] 886
Defective Remote Positioner RAISE Selection Switch System 886
Failure Code: [WRK-5] 888
Defective Remote Positioner LOWER ON/OFF Switch System 888
Failure Code: [WRK-6] 890
Defective Bucket Cylinder Proximity Switch System 890
Failure Code: [WRK-7] 892
Defective Bucket Cylinder Full Stroke Detection Switch System 892
Failure Code: [WRK-8] 894
Defective Semi-Automatic Digging HARD Selection Switch System 894
Failure Code: [WRK-9] 896
Defective Semi-Automatic Digging SOFT Selection Switch System 896
Failure Code: [WRK-10] 898
Defective Joystick ON/OFF Switch System 898
Failure Code: [WRK-11] 900
Defective Joystick Steering Speed HI/LO Switch System 900
Failure Code: [WRK-12] 902
Defective Joystick Solenoid Cut Relay Output System 902
Failure Code: [WRK-13] 903
Hot Short-Circuited Lift Arm RAISE Magnet Detent Output System 903
Failure Code: [WRK-14] 904
Hot Short-Circuited Lift Arm FLOAT Magnet Detent Output System 904
Failure Code: [WRK-15] 905
Hot Short-Circuited Bucket TILT Magnet Detent Output System 905
Failure Code: [WRK-16] 906
Hot Short-Circuited Work Equipment Neutral Lock Solenoid Output System 906
Failure Code: [WRK-17] 907
Hot Short-Circuited Lift Arm RAISE EPC Solenoid System 907
Failure Code: [WRK-18] 908
Hot Short- Circuited Lift Arm LOWER EPC Solenoid System 908
Failure Code: [WRK-19] 909
Hot Short- Circuited Bucket TILT EPC Solenoid System 909
Failure Code: [WRK-20] 910
Hot Short- Circuited Bucket DUMP EPC Solenoid System 910
Failure Code: [WRK-21] 911
Hot Short- Circuited 3 Valves Extension EPC Solenoid System 911
Failure Code: [WRK-22] 912
Hot Short- Circuited 3 Valves Retraction EPC Solenoid System 912
Failure Code: [WRK-23] 913
Short in Joystick Steering Right EPC Solenoid System 913
Failure Code: [WRK-24] 914
Short in Joystick Steering Left EPC Solenoid System 914
Failure Code: [WRK-25] 916
Failure Code: [WRK-26] 918
Defective Boom Kick-Out Function and Cancellation 918
Failure Code: [WRK-27] 921
Defective Bucket Leveler Function and Cancellation 921
Failure Code: [WRK-28] 924
Defective Lift Arm FLOAT Holding and Cancellation 924
MONITOR SYSTEM (MON MODE) 926
Connector Types and Locations 926
Connector Layout Drawing 933
Monitor System Diagram 939
Failure Code [2F00KM] 943
Dragging Parking Brake 943
Failure Code [2G42ZG] 946
Accumulator Oil Pressure (Front Brake Circuit) Low 946
Failure Code [2G43ZG] 948
Accumulator Oil Pressure (Rear Brake Circuit) Low 948
Failure Code [AA1ANX] 950
Air Cleaner 1 Clogged 950
Failure Code [AB00L6] 952
Defective Battery Charging Circuit 952
Failure Code [AB00MA] 954
The Battery Charging Circuit is Out of Order 954
Failure Code [B@BAZG] 956
Engine Oil Pressure Low 956
Failure Code [B@BAZK] 957
Engine Oil Level Low 957
Failure Code [B@BCNS] 958
Engine Coolant Temperature Overheating 958
Failure Code [B@BCZK] 960
Alarm Indicating Low Coolant Level 960
Failure Code [B@HANS] 961
Hydraulic Oil Temperature Overheating 961
Failure Code [B@CENS] 962
Torque Converter Oil Temperature Overheating 962
Failure Code [D182KZ] 964
The Preheater Relay Coil is Open or Shorted 964
Failure Code [D5ZHL6] 966
Start Switch C (IGN “C”) Input Failure 966
Failure Code [DA80L4] 968
Auto Grease Input is Abnormal 968
Failure Code [DAF3KK] 970
When the SW Power Supply (for Operation) is ON, the NSW Power Supply (for Memory) is OFF 970
Failure Code [DAF5KP] 972
5-V Power Supply Output Failure 972
Failure Code [DAF6KP] 974
24-V Power Supply Output Failure 974
Failure Code [DAFBKM] 976
Incorrect Information on Model Selection 976
Failure Code [DAFSKQ] 977
Incorrect Information on Meter Indication Selection 977
Failure Code [DAQSKR] 978
S-NET Communication Failure (Between Monitor Panel and Transmission Controller) 978
Failure Code [DBQSKR] 980
S-NET Communication Failure (Between Monitor Panel and Work Equipment Controller) 980
Failure Code [DB9SKR] 982
S-NET Communication Failure (Between Monitor Panel and Work Equipment Controller) 982
Failure Code [DD15LD] 984
Monitor Panel Mode Selector Switch 1 [n] (Panel SW1) Input Error 984
Failure Code [DD16LD] 986
Monitor Panel Mode Selector Switch 1 [‡] (Panel SW2) Input Error 986
Failure Code [DD17LD] 988
Monitor Panel Mode Selector Switch 2 [<] (Panel SW3) Input Error 988
Failure Code [DD18LD] 990
Monitor Panel Mode Selector Switch 2 [>] (Panel SW4) Input Error 990
Failure Code [DD1CLD] 992
Sub-Total Switch Failure 992
Failure Code [DDK3KM] 994
CAUTION: Right FNR Switch is in “N” (Neutral) 994
Failure Code [DDK4KM] 995
CAUTION: Joystick FNR Switch is in “N” (Neutral) 995
Failure Code [DDK6KM] 996
CAUTION: FNR (Forward- Reverse) Lever Switch is in “N” (Neutral) 996
Failure Code [DDS5L6] 998
Decreased Steering Oil Pressure 998
Failure Code [DDY0LD] 1000
Cancel Switch Failure 1000
Failure Code [DGE2KX] 1002
Engine Coolant Temperature (High Temperature) Sensor System Failure 1002
Failure Code [DGE3L6] 1004
Abnormal Connection of Engine Coolant Temperature (Low Temperature) Sensor System 1004
Failure Code [DGH2KX] 1006
Hydraulic Oil Temperature Sensor System Failure 1006
Failure Code [DGT1KX] 1007
Torque Converter Oil Temperature Sensor System Failure 1007
Failure Code [DHE4L6] 1008
Engine Oil Pressure Sensor System Failure 1008
Failure Code [DHPCKX] 1010
Bottom Pressure Sensor Failure 1010
Failure Code [DHPDKX] 1012
Head Pressure Sensor Failure 1012
Failure Code [DKA0KX] 1014
Lift Arm Angle Sensor Failure 1014
Failure Code [DV00KB] 1016
Shorted Alarm Buzzer Output System 1016
Failure Code [DY30ME] 1018
The Emergency Steering Remains Actuated For More Than One Minute 1018
Troubleshooting Code [MON-1] 1022
The Parking Brake Indicator Lamp Does Not Light Up When the Parking Brake Switch is Turned ON 1022
Troubleshooting Code [MON-2] 1024
Circuit Diagnostic Procedures for Error Code 1024
Troubleshooting Code [MON-3] 1026
The Brake Oil Pressure Caution Lamp Does Not Light Up When the Emergency Brake is Applied (Rear Circuit) 1026
Troubleshooting Code [MON-4] 1028
The Air Cleaner Clogging Indicator Lamp Does Not Light 1028
Troubleshooting Code [MON-5] 1030
The Engine Oil Pressure Caution Lamp Does Not Light 1030
Troubleshooting Code [MON-6] 1031
The Engine Oil Level Caution Lamp Does Not Light 1031
Troubleshooting Code [MON-7] 1032
The Engine Coolant Temperature Caution Lamp Does Not Light 1032
Troubleshooting Code [MON-8] 1033
The Coolant Level Caution Lamp Does Not Light 1033
Troubleshooting Code [MON-9] 1034
The Hydraulic Oil Temperature Caution Lamp Does Not Light 1034
Troubleshooting Code [MON-10] 1035
The Torque Converter Oil Temperature Caution Lamp Does Not Light 1035
Troubleshooting Code [MON-11] 1036
The Steering Hydraulic Caution Lamp Does Not Light 1036
Troubleshooting Code [MON-12] 1038
Input Fault in Monitor Panel Mode Switch 1 [n] (Panel SW1) 1038
Troubleshooting Code [MON-13] 1040
Input Fault in Monitor Panel Mode Switch 1 [‡] (Panel SW2) 1040
Troubleshooting Code [MON-14] 1042
Input Fault in Monitor Panel Mode Switch 2 [<] (Panel SW3) 1042
Troubleshooting Code [MON-15] 1044
Input Fault in Monitor Panel Mode Switch 2 [>] (Panel SW4) 1044
Troubleshooting Code [MON-16] 1046
Defective Subtotal Switch 1046
Troubleshooting Code [MON-17] 1048
Defective Cancel Switch 1048
Troubleshooting Code [MON-18] 1050
Defective Bottom Pressure Sensor (Short Fault) 1050
Troubleshooting Code [MON-19] 1052
Defective Head Sensor 1052
Troubleshooting Code [MON-20] 1054
The Alarm Buzzer Does Not Sound or Stop 1054
HYDRAULIC AND MECHINCAL SYSTEMS (H MODE) 1056
H-1 – The Machine Does Not Move 1056
H-2 – The Lock-up Clutch is Not Released (The Engine Stops) (When the Lock-up Clutch is Provided) 1058
H-3A – The Travel Speed is Slow, Thrusting Force is Weak, Uphill Traveling Power is Weak, and the Gear is Not Shifted 1059
H-3B – The Torque Converter Lock-up Clutch is Not Let in (When Lock-up Clutch is Provided) 1061
H-4 – Shocks are Large at the Times of Starting and Shifting Gear 1062
H-5 – Time Lag is Large at the Times of Starting and Shifting Gear 1064
H-6 – Torque Converter Oil Temperature is High 1066
H-7 – Steering Wheel Does Not Turn 1067
H-8 – Steering Does Not Turn [Machine With Joystick] 1068
H-9 – Turning, Response of Steering is Poor 1069
H-10 – Steering is Heavy 1070
H-11 – Steering Wheel Shakes or Jerks 1071
H-12 – The Brake Does Not Work 1072
H-13 – The Brake is Not Released or is Draging 1073
H-14 – The Parking Brake is Not Released or Draging 1074
H-15 – The Boom Does Not Rise 1075
H-16 – The Boom Moves Slowly or the Boom Rising Force is Insufficient 1076
H-17 – When Rising, the Boom Comes to Move Slowly at Specific Height 1077
H-18 – The Boom Cylinder Cannot Hold Down the Bucket (the Bucket Rises in the Air) 1077
H-19 – Hydraulic Drifts of the Boom Occur Often 1077
H-20 – The Boom Wobbles During Operation 1078
H-21 – When the Control Lever is Switched From “Hold” to “Raise,” the Boom Falls Temporarily 1078
H-22 – The Bucket Does Not Tilt Back 1079
H-23 – The Bucket Moves Slowly or the Tilting Back Force is Insufficient 1080
H-24 – The Bucket Comes to Operate Slowly in the Midst of Tilting-back 1081
H-25 – The Bucket Cylinder Cannot Hold Down the Bucket 1081
H-26 – Hydraulic Drifts of the Bucket Occur Often 1081
H-27 – The Bucket Wobbles During Travel with Cargo (The Work Equipment Valve is Set to “Hold”) 1082
H-28 – When the Control Lever is Switched From “Hold” to “Tilt,” The Bucket Falls Temporarily 1082
H-29 – The Control Levers of Boom and Bucket Do Not Move Smoothly and Heavy 1083
H-30 – E C S S Does Not Work and There is Pitching and Bouncing 1084
ELECTRICAL SYSTEM (E MODE) 1085
Connector Types and Locations 1085
Connector Layout Drawing 1092
Electrical System Diagram 1098
Action Code: [E-1-a] 1099
The Engine Does Not Crank (Ignition System) 1099
Action Code: [E-1-b] 1104
The Engine Does Not Start (Engine Stop Solenoid System) 1104
Action Code: [E-2] 1108
The Engine Does Not Shut Down 1108
Action Code: [E-3] 1110
Preheating Inoperable or Remains ON 1110
Action Code: [E-4] 1114
The Engine Power Mode Inoperable 1114
Action Code: [E-5] 1118
The Front Wiper Does Not Function 1118
Action Code: [E-6] 1122
The Rear Wiper Does Not Function 1122
Action Code: [E-7] 1126
The Side Wiper Does Not Function (If Equipped) 1126
Action Code: [E-8] 1130
The Window Washer Does Not Function 1130
Action Code: [E-9] 1134
The Headlamp (Lo Beam) Does Not Function 1134
Action Code: [E-10] 1138
The Headlamp (Hi Beam) Does Not Function 1138
Action Code: [E-11] 1142
Clearance Lamps Do Not Function 1142
Action Code: [E-12] 1146
Turn Signal Does Not Function 1146
Action Code: [E-13] 1150
Horn Does Not Sound 1150
Action Code: [E-14] 1152
Air Conditioner Does Not Work or Does Not Shut Down 1152
ENGINE SYSTEM (S-MODE) 1156
Method Of Using Troubleshooting Charts 1156
(S-1) Engine Starting Performance Is Poor 1160
(S-2) Engine Does Not Crank 1161
Engine Cranks But No Exhaust Smoke Comes Out Of Stack 1162
Smoke Comes Out Of Stack But Engine Does Not Start 1163
(S-3) Engine Does Not Run Smoothly 1164
(S-4) Engine Stops During Operations 1165
(S-5) Engine Speed Hunts 1166
(S-6) Engine Lacks Power 1167
(S-7) Exhaust Smoke Is Black 1169
(S-8) Oil Consumption Is Excessive Or Exhaust Smoke Is Blue 1170
(S-9) Oil Becomes Contaminated Quickly 1171
(S-10) Fuel Consumption Is Excessive 1172
(S-11) Oil Found In Coolant, Or Coolant Spurts From Radiator 1173
(S-12) Oil Pressure Caution Lamp Lights Up 1174
(S-13) Oil Level Rises (Coolant Or Fuel Found In Oil) 1175
(S-14) Coolant Temperature Too High (Overheating) 1176
(S-15) Abnormal Noise Is Heard When Engine Is Running 1177
(S-16) Excessive Vibration When Engine Is Running 1178
50 DISASSEMBLY AND ASSEMBLY 1179
HOW TO READ THIS MANUAL 1183
Removal and Installation of Assemblies 1183
Special Tools 1183
Removal 1183
Installation 1183
Disassembly and Assembly of Assemblies 1184
Special Tools 1184
Disassembly 1184
Assembly 1185
SPECIAL TOOLS LIST 1186
Special Tool Illustrations 1189
CONNECTOR REPAIR PROCEDURES 1198
Stripping Insulation 1198
Wire Inspection 1198
Contact Terminal Removal (HD30 Type) 1199
Crimping Contact Terminal (HD30 Type) 1200
Insertion of Contact Terminal (HD30 Type) 1201
Contact Terminal Removal (DT Type) 1202
Crimping Contact Terminal (DT Type) 1203
Insertion of Contact Terminal (DT Type) 1204
BULKHEAD ASSEMBLY 1205
Removal 1205
Installation 1206
ENGINE HOOD ASSEMBLY 1207
Removal 1207
Installation 1208
ENGINE ASSEMBLY 1209
Removal 1209
Installation 1212
ENGINE CYLINDER HEAD ASSEMBLY 1214
Special Tool 1214
Removal 1214
Installation 1219
RADIATOR FAN MOTOR 1222
Removal 1222
Installation 1223
AFTERCOOLER 1224
Removal 1224
Installation 1224
FUEL INJECTION PUMP 1225
Special Tools 1225
Removal 1225
Installation 1228
NOZZLE HOLDER 1230
Removal 1230
Installation 1232
FAN AND FAN MOTOR 1233
Removal 1233
Installation 1234
FUEL TANK 1235
Removal 1235
Installation 1237
PARKING BRAKE DISCS AND PLATES 1238
Special Tools 1238
Removal 1238
Installation 1240
TORQUE CONVERTER AND TRANSMISSION 1242
Removal 1242
Installation 1247
Bleeding the Hydraulic Brake Circuit 1247
TRANSMISSION ASSEMBLY 1248
Special Tools 1248
Disassembly 1248
Assembly 1255
TRANSMISSION CLUTCH PACK 1264
Special Tools 1264
Disassembly 1264
Forward and Reverse Clutch Packs 1264
1st and 4th Clutch Pack 1266
2nd and 3rd Clutch Pack 1270
Assembly 1273
Forward and Reverse Clutch Packs 1273
1st and 4th Clutch Pack 1277
2nd and 3rd Clutch Pack 1281
PARKING BRAKE 1286
Special Tools 1286
Disassembly 1286
Assembly 1289
TORQUE CONVERTER (STANDARD) 1295
Special Tools 1295
Disassembly 1295
Assembly 1298
TORQUE CONVERTER (LOCK-UP) 1301
Special Tools 1301
Disassembly 1301
Assembly 1305
REAR AXLE 1309
Removal 1309
Installation 1311
FRONT AXLE 1313
Removal 1313
Installation 1314
AXLE HOUSING 1315
Special Tools 1315
Disassembly 1315
Assembly 1320
DIFFERENTIAL 1326
Special Tools 1326
Disassembly 1327
Assembly 1335
CENTER HINGE PIN 1350
Special Tools 1350
Removal 1350
Installation 1356
CAB ASSEMBLY 1360
Removal 1360
Installation 1361
CAB AND FLOOR FRAME 1362
Removal 1362
Installation 1365
OPERATOR’S CAB GLASS (SEALED GLASS) 1366
Special Tools 1366
Removal 1366
Installation 1368
HYDRAULIC PUMP ASSEMBLY 1376
Removal 1376
Installation 1376
Steering, Switching, and Fan Pump Assembly 1377
Removal 1377
Installation 1377
STEERING DEMAND VALVE ASSEMBLY 1378
Removal 1378
Installation 1379
Disassembly 1380
Assembly 1384
ORBITROL VALVE 1388
Removal 1388
Installation 1390
Disassembly 1390
Assembly 1393
ECSS VALVE 1398
Removal 1398
Installation 1398
WORK EQUIPMENT VALVE 1399
Removal 1399
Installation 1401
HYDRAULIC CYLINDERS 1402
Steering, Lift, and Bucket 1402
Special Tools 1402
Disassembly 1403
Assembly 1407
HYDRAULIC TANK ASSEMBLY 1414
Removal 1414
Installation 1415
WORK EQUIPMENT 1416
Removal 1416
Installation 1420
COUNTERWEIGHT 1422
Removal 1422
Installation 1422
AIR CONDITIONER ASSEMBLY 1423
Special Tools 1423
Removal 1423
Installation 1426
AIR CONDITIONER COMPRESSOR 1428
Special Tools 1428
Removal 1428
Installation 1429
OPERATOR’S SEAT ASSEMBLY 1430
Disassembly 1430
Assembly 1438
90 OTHERS 1443
POWER TRAIN OIL CIRCUIT DIAGRAM 1444
WITHOUT TORQUE CONVERTER LOCKUP CLUTCH 1444
WITH TORQUE CONVERTER LOCKUP CLUTCH 1445
BRAKE OIL CIRCUIT DIAGRAM 1446
HYDRAULIC CIRCUIT SCHEMATIC 1447
ELECTRICAL SCHEMATIC 1449
STANDARD 1449
FLOOR HARNESS – CAB 1449
FLOOR HARNESS – TRANSMISSION CONTROLLER 1451
FLOOR HARNESS – TRANSMISSION HARNESS 1453
FLOOR HARNESS – REAR HARNESS 1455
FLOOR HARNESS – RELAY UNITS 1457
WITH JOYSTICK STEERING 1459
FLOOR HARNESS – CAB 1459
FLOOR HARNESS – TRANSMISSION CONTROLLER 1461
FLOOR HARNESS – JOYSTICK HARNESS 1463
FLOOR HARNESS – TRANSMISSION HARNESS 1465
FLOOR HARNESS – REAR HARNESS 1467
FLOOR HARNESS – RELAY UNITS 1469
ENGINE HARNESS 1471
REAR HARNESS 1473
FRONT FRAME HARNESS 1475
CAB HARNESS 1477
MONITOR PANEL CONTROLLER 1479
A/C RELAY HARNESS 1481
TRANSMISSION HARNESS 1483
JOYSTICK CONTROLLER HARNESS 1485
KOMTRAX HARNESS 1487

S.V 15/12/24