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Komatsu WA380-6 Wheel Loader Shop Manual PDF Download
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- Komatsu WA380-6 WHEEL LOADER Service Repair Manual
- SERIAL NUMBERS WA380-6 A54001 and up
- PUBLICATION NUMBER:CEBM022703
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Description
Komatsu WA380-6 WHEEL LOADER Service Repair Manual
Screenshot of the Manual:
KOMATSU WA380-6 WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
Description:
Komatsu WA380-6 WHEEL LOADER Service Repair Manual
- 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 judgments. 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 judgment standards when inspecting disassembled parts.
- Standard Value Table This section explains the standard values for a new machine and the judgment 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.
- Other This section has the foldout drawings for the machine.
Table of Contents:
Komatsu WA380-6 WHEEL LOADER Service Repair Manual
CEBM022703 - WA380-6 S/N A54001-UP.pdf.............................................................................................................. 0 01 GENERAL...................................................................................................................................... 63 SPECIFICATIONS.............................................................................................................................. 65 Dimension Drawing....................................................................................................................... 65 Specification Tables.................................................................................................................... 67 WEIGHT TABLE................................................................................................................................ 72 FUEL, COOLANT, AND LUBRICANTS............................................................................................................... 74 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD................................................................................................. 77 ENGINE AND COOLING SYSTEM................................................................................................................... 82 Engine and Transmission Mounting........................................................................................................ 82 Torque Values....................................................................................................................... 83 Cooling System.......................................................................................................................... 84 Specifications...................................................................................................................... 84 Cooling Fan Pump........................................................................................................................ 86 Type: LPV30......................................................................................................................... 86 Torque Values....................................................................................................................... 87 Torque Values....................................................................................................................... 88 Function............................................................................................................................ 89 Structure........................................................................................................................... 89 Operation........................................................................................................................... 90 Control of Delivery................................................................................................................. 90 Servo Valve............................................................................................................................. 91 Torque Values....................................................................................................................... 91 Function............................................................................................................................ 92 Cooling Fan Motor System................................................................................................................ 94 Type: LMF28......................................................................................................................... 94 Specifications...................................................................................................................... 95 Torque Values....................................................................................................................... 95 Hydraulic Motor......................................................................................................................... 97 Function............................................................................................................................ 97 Principle of Operation.............................................................................................................. 97 Suction Valve........................................................................................................................... 98 Function............................................................................................................................ 98 Operation........................................................................................................................... 98 Reversible Valve........................................................................................................................ 99 Safety Valve............................................................................................................................ 100 Function............................................................................................................................ 100 Operation........................................................................................................................... 100 POWER TRAIN SYSTEM.......................................................................................................................... 101 Drive Line Components................................................................................................................... 101 Outline............................................................................................................................. 101 System Diagram.......................................................................................................................... 102 Outline............................................................................................................................. 103 Drive Shaft System...................................................................................................................... 104 Torque Values....................................................................................................................... 104 Outline............................................................................................................................. 104 Power Train Piping System............................................................................................................... 105 Torque Converter........................................................................................................................ 106 Without Lockup Clutch............................................................................................................... 106 Specifications.................................................................................................................. 106 Torque Values................................................................................................................... 107 Power Transmitting Route............................................................................................................ 108 Oil Flow............................................................................................................................ 108 With Lockup Clutch.................................................................................................................. 109 Specification................................................................................................................... 109 Torque Values................................................................................................................... 111 Torque Flow............................................................................................................................. 112 When Lockup Clutch Is Disengaged.................................................................................................... 112 When Lockup Clutch Is Engaged....................................................................................................... 112 Oil Flow............................................................................................................................ 113 Transmission............................................................................................................................ 114 With Lockup Clutch.................................................................................................................. 114 Torque Values................................................................................................................... 115 Outline......................................................................................................................... 116 Torque Values................................................................................................................... 119 Torque Values................................................................................................................... 123 Forward and Reverse Clutches............................................................................................................ 124 Without Lockup Clutch............................................................................................................... 124 With Lockup Clutch.................................................................................................................. 125 1st and 4th Clutches................................................................................................................ 126 2nd and 3rd Clutches................................................................................................................ 127 Operation of Clutch Pack............................................................................................................ 128 When clutch is engaged.......................................................................................................... 128 When clutch is disengaged....................................................................................................... 128 Transmission Torque Flow Route.......................................................................................................... 130 Forward 1st Gear Speed.............................................................................................................. 130 Forward 2nd Gear Speed.............................................................................................................. 131 Forward 3rd Gear Speed.............................................................................................................. 133 Forward 4th Gear Speed.............................................................................................................. 134 Reverse 1st Gear Speed.............................................................................................................. 136 Flow Control Valve...................................................................................................................... 137 Torque Values....................................................................................................................... 139 Operation........................................................................................................................... 139 Valve Assembly...................................................................................................................... 140 Torque Values................................................................................................................... 141 ECMV System............................................................................................................................. 142 For R, 1st, and 2nd Clutches........................................................................................................ 142 Torque Values................................................................................................................... 143 For F, 3rd, 4th, and Lockup Clutches................................................................................................ 144 ECMV For Gear Speed Clutch.......................................................................................................... 146 Outline of ECMV................................................................................................................. 146 ECMV and Proportional Solenoid.................................................................................................. 146 ECMV and Fill Switch............................................................................................................ 146 Operation of ECMV............................................................................................................... 147 Before Shifting Gear (when draining) (Range A in chart)......................................................................... 147 During filling (Range B in chart)............................................................................................... 148 Pressure regulation (Range C in chart).......................................................................................... 148 ECMV for Lockup Clutch.............................................................................................................. 149 Outline......................................................................................................................... 149 Operation....................................................................................................................... 149 When Traveling in Direct Range.................................................................................................. 150 During Filling.................................................................................................................. 150 Pressure Adjustment............................................................................................................. 150 Main and Torque Converter Relief Valve System........................................................................................... 152 Torque Values....................................................................................................................... 153 Outline............................................................................................................................. 154 Torque Converter Relief Valve................................................................................................... 154 Main Relief Valve............................................................................................................... 154 Operation........................................................................................................................... 154 Torque Converter Relief Valve................................................................................................... 154 Operation of Main Relief Valve.................................................................................................. 154 DRIVE AXLE SYSTEM........................................................................................................................... 155 Front Axle Assembly..................................................................................................................... 155 Rear Axle Assembly...................................................................................................................... 156 Front Differential...................................................................................................................... 158 Torque Values....................................................................................................................... 159 Rear Differential....................................................................................................................... 160 Torque Values....................................................................................................................... 161 Outline............................................................................................................................. 162 While Machine is Traveling Straight................................................................................................. 162 When Machine Is Turning............................................................................................................. 162 Limited Slip Differential............................................................................................................... 163 Front Axle Carrier...................................................................................................................... 164 Torque Values....................................................................................................................... 165 Rear Axle Carrier....................................................................................................................... 166 Torque Values....................................................................................................................... 167 Operation of Limited Slip Differential.............................................................................................. 168 Generation of Braking Torque by Right / Left Side Gears (5)......................................................................... 168 While Machine is Traveling Straight................................................................................................. 168 When Machine Is Turning............................................................................................................. 169 Final Drive............................................................................................................................. 170 Outline............................................................................................................................. 170 Torque Values....................................................................................................................... 171 STEERING SYSTEM............................................................................................................................. 172 Steering Piping Diagram................................................................................................................. 172 Steering Column......................................................................................................................... 173 Torque Values....................................................................................................................... 173 Steering Pump........................................................................................................................... 174 Type: LPV63......................................................................................................................... 174 Torque Values....................................................................................................................... 175 Pump Unit........................................................................................................................... 176 Torque Values................................................................................................................... 177 Function........................................................................................................................ 178 Structure....................................................................................................................... 178 Operation of Pump............................................................................................................... 179 Control of Discharge Amount..................................................................................................... 180 Servo Valve......................................................................................................................... 181 Torque Values................................................................................................................... 183 LS Valve............................................................................................................................ 184 Function........................................................................................................................ 184 PC Valve............................................................................................................................ 184 Function........................................................................................................................ 184 Operation of Spring............................................................................................................. 185 When pump pressure (PA) is low.................................................................................................. 185 When pump pressure (PA) is high................................................................................................. 186 Steering Valve.......................................................................................................................... 188 Operation of Flow Amplifier......................................................................................................... 192 When Spool is at Neutral (when Orbitrol valve is not in operation).............................................................. 192 When Spool is in Operation (when oil flows in port (Pa))........................................................................ 192 When Spool is Returned (when steering wheel is stopped)......................................................................... 193 Operation of Flow Control Spool..................................................................................................... 194 When Steering Spool is at Neutral Position...................................................................................... 194 When Steering Spool Operates.................................................................................................... 195 Operation of Steering Valve......................................................................................................... 196 At Neutral...................................................................................................................... 196 Turning Left.................................................................................................................... 197 Turning Right................................................................................................................... 198 Steering Relief Valve............................................................................................................... 199 Function........................................................................................................................ 199 Operation....................................................................................................................... 199 Overload Relief Valve............................................................................................................... 200 Function........................................................................................................................ 200 Operation as Relief Valve....................................................................................................... 200 Operation as Suction Valve...................................................................................................... 201 Relief Valve........................................................................................................................ 201 Function........................................................................................................................ 201 Orbitrol Valve.......................................................................................................................... 202 Torque Values....................................................................................................................... 202 Outline............................................................................................................................. 203 Structure........................................................................................................................... 203 Connection of Hand Pump and Sleeve.................................................................................................. 204 Role of Centering Spring............................................................................................................ 205 Stop Valve.............................................................................................................................. 206 Steering Relief Valve................................................................................................................... 207 Torque Values....................................................................................................................... 207 Outline............................................................................................................................. 207 Steering Cylinder....................................................................................................................... 208 Emergency Steering Motor................................................................................................................ 210 Function............................................................................................................................ 210 Specifications...................................................................................................................... 210 Emergency Steering Pump (If Equipped)................................................................................................... 211 Type: SBL (1) 21.................................................................................................................... 211 Torque Value........................................................................................................................ 211 Function............................................................................................................................ 211 Joystick Steering Lever Linkage......................................................................................................... 212 Steering Electric Lever................................................................................................................. 213 Function............................................................................................................................ 213 Joystick EPC Valve...................................................................................................................... 214 Torque Values....................................................................................................................... 214 Function............................................................................................................................ 214 Multi-Function Lever & Joystick Lever (Modification).................................................................................... 215 Required............................................................................................................................ 215 Procedure........................................................................................................................... 216 SERVICE BRAKING SYSTEM...................................................................................................................... 217 Brake Piping Diagram.................................................................................................................... 217 Charge Valve............................................................................................................................ 218 Torque Value........................................................................................................................ 218 Torque Values....................................................................................................................... 221 Function............................................................................................................................ 221 Operation........................................................................................................................... 222 When Oil is Not Supplied to Accumulator (cut-out state)............................................................................. 222 When Oil is Supplied to Accumulator (cut-in state).................................................................................. 223 When Cut-out Pressure is Reached.................................................................................................... 224 Main Relief Valve (R1).............................................................................................................. 224 PPC Relief Valve (R3)............................................................................................................... 225 Sequence Valve (H1)................................................................................................................. 225 Shuttle Valve (S1).................................................................................................................. 225 Brake Valve............................................................................................................................. 226 Outline............................................................................................................................. 226 Operation........................................................................................................................... 227 When the Brake Pedal is Depressed................................................................................................... 227 When Brake on One Side is Operated.................................................................................................. 228 Balancing Operation................................................................................................................. 229 When Brake Pedal is Released........................................................................................................ 230 Accumulator (for Brakes)................................................................................................................ 231 Function............................................................................................................................ 231 Specifications...................................................................................................................... 231 Front Brake............................................................................................................................. 232 Outline............................................................................................................................. 233 Rear Brake.............................................................................................................................. 234 Outline............................................................................................................................. 235 Operation........................................................................................................................... 235 When Brake is Operated.............................................................................................................. 235 When Brake is Released.............................................................................................................. 235 PARKING BRAKE SYSTEM........................................................................................................................ 236 Brake Control........................................................................................................................... 236 Outline............................................................................................................................. 237 Parking Brake Unit...................................................................................................................... 238 Outline............................................................................................................................. 239 Torque Values....................................................................................................................... 239 Parking Brake Solenoid Valve............................................................................................................ 240 Torque Values....................................................................................................................... 240 Operation........................................................................................................................... 241 When Parking Brake is Applied (When solenoid is de-energized)....................................................................... 241 When Parking Brake is Released (When solenoid is energized)......................................................................... 241 Emergency Parking Brake Release Valve................................................................................................... 242 Function............................................................................................................................ 242 UNDERCARRIAGE AND FRAME..................................................................................................................... 243 Axle Mounting and Center Hinge Pin...................................................................................................... 243 Torque Values....................................................................................................................... 243 Outline............................................................................................................................. 243 Torque Values....................................................................................................................... 244 Tires................................................................................................................................... 248 Radial Ply Tire..................................................................................................................... 248 Bias Tire........................................................................................................................... 248 HYDRAULIC SYSTEM............................................................................................................................ 250 Piping Diagram.......................................................................................................................... 250 Outline............................................................................................................................. 252 Work Equipment Control Lever System..................................................................................................... 253 Multi-Function Mono-Lever Type.......................................................................................................... 254 Hydraulic Tank.......................................................................................................................... 256 Specifications...................................................................................................................... 257 Tank Vent System.................................................................................................................... 257 Power Train Pump........................................................................................................................ 258 Type: SDL (30)80.................................................................................................................... 258 Outline............................................................................................................................. 258 Work Equipment Pump..................................................................................................................... 260 Type: LPV90......................................................................................................................... 260 Torque Values....................................................................................................................... 261 Pump Unit........................................................................................................................... 262 Servo Valve......................................................................................................................... 264 Torque Values................................................................................................................... 267 Function........................................................................................................................ 268 Structure....................................................................................................................... 268 Operation of Pump............................................................................................................... 269 Control of Delivery............................................................................................................. 270 LS Valve............................................................................................................................ 270 Function........................................................................................................................ 270 PC valve............................................................................................................................ 271 Function........................................................................................................................ 271 Operation....................................................................................................................... 271 When Load is Light (Fig.1)...................................................................................................... 272 When Load is Heavy (Fig.2)...................................................................................................... 272 When Balanced (Fig.3)........................................................................................................... 273 Work Equipment Control Valve............................................................................................................ 274 Outline............................................................................................................................. 274 4-Spool Valve....................................................................................................................... 276 General View.................................................................................................................... 276 Torque Values................................................................................................................... 277 Sectional View of Valve (1/7)................................................................................................... 278 Torque Values................................................................................................................... 279 Sectional View of Valve (2 /7).................................................................................................. 280 Sectional View of Valve (3/7)................................................................................................... 282 Sectional View of Valve (4/7)................................................................................................... 284 Sectional View of Valve (5/7)................................................................................................... 286 Sectional View of Valve (6/7)................................................................................................... 288 Sectional View of Valve (7/7)................................................................................................... 290 CLSS.................................................................................................................................... 292 Outline of CLSS..................................................................................................................... 292 Features........................................................................................................................ 292 Structure....................................................................................................................... 292 Basic Principle..................................................................................................................... 293 Pump Swash Plate Angle Control.................................................................................................. 293 Pressure Compensation Control....................................................................................................... 294 Function and Operation of Each Valve.................................................................................................... 295 Hydraulic Circuit Diagram of Valves................................................................................................. 295 Unload Valve........................................................................................................................ 296 When Control Valve is at Neutral Position....................................................................................... 296 When Control Valve is Controlled Finely......................................................................................... 297 When Control Valve is Operated.................................................................................................. 298 Work Equipment Valve (Supply of LS Pressure)........................................................................................ 299 Work Equipment Valve (Lift Arm)................................................................................................. 299 Work Equipment Valve (Bucket and Service)....................................................................................... 300 LS Bypass Plug...................................................................................................................... 301 Pressure Compensation Valve......................................................................................................... 302 Lift Arm Regeneration Circuit....................................................................................................... 306 When Lift Arm is Lowered........................................................................................................ 306 Function........................................................................................................................ 307 Operation....................................................................................................................... 307 Variable Lift Check Valve........................................................................................................... 308 Function........................................................................................................................ 308 Operation....................................................................................................................... 308 ECSS Control Valve...................................................................................................................... 309 Function............................................................................................................................ 309 Operation........................................................................................................................... 309 Restriction on Lift Arm Raise Stroke................................................................................................ 310 Function............................................................................................................................ 311 Operation........................................................................................................................... 311 Accumulator Charge Valve................................................................................................................ 312 Pressure............................................................................................................................ 313 When Valve is in Neutral and (P) is Low............................................................................................. 314 Function............................................................................................................................ 314 Operation........................................................................................................................... 314 When Load Pressure (P) is High...................................................................................................... 315 Operation........................................................................................................................... 315 PPC Valve............................................................................................................................... 316 Work Equipment PPC Valve............................................................................................................ 316 Operation........................................................................................................................... 318 When In Neutral..................................................................................................................... 318 During Fine Control................................................................................................................. 319 Stabilizer Valve........................................................................................................................ 321 Function............................................................................................................................ 321 When in Neutral..................................................................................................................... 322 Operation........................................................................................................................... 322 Main Spool (9) is Moved from Neutral to Operating Position.......................................................................... 323 Operation........................................................................................................................... 323 Main Spool (9) is Moved from Operating Position to Neutral.......................................................................... 325 Operation........................................................................................................................... 325 Work Equipment PPC Cutoff Solenoid Valve................................................................................................ 326 Outline............................................................................................................................. 326 Operation........................................................................................................................... 327 Accumulator (for PPC Circuit)........................................................................................................... 328 Outline............................................................................................................................. 328 Specifications...................................................................................................................... 328 Accumulator (for ECSS).................................................................................................................. 329 Function............................................................................................................................ 329 Specifications...................................................................................................................... 329 WORK EQUIPMENT.............................................................................................................................. 330 Work Equipment Linkage.................................................................................................................. 330 Bucket.................................................................................................................................. 332 Bucket Positioner and Boom Kickout...................................................................................................... 334 Bucket Positioner................................................................................................................... 335 Boom Kick-out....................................................................................................................... 335 Proximity Switch.................................................................................................................... 336 When Bucket Is Tilted........................................................................................................... 336 Function of Proximity Switch.................................................................................................... 338 When Lift Arm Is Raised......................................................................................................... 339 Function of Proximity Switch.................................................................................................... 341 Work Equipment Cylinders................................................................................................................ 342 Lift Cylinder....................................................................................................................... 342 Bucket Cylinder..................................................................................................................... 342 CAB ENVIRONMENT............................................................................................................................. 343 ROPS Cab................................................................................................................................ 343 Air Conditioner......................................................................................................................... 344 Air Conditioner Piping Diagram...................................................................................................... 344 Specifications.................................................................................................................. 345 Refrigerant Circuit Diagram......................................................................................................... 346 Air Conditioner Unit................................................................................................................ 347 (Automatic Air Conditioner)..................................................................................................... 347 Outline......................................................................................................................... 348 Cooler.......................................................................................................................... 348 Heater.......................................................................................................................... 348 Functions of Major Components................................................................................................... 348 Evaporator...................................................................................................................... 348 Heater Core..................................................................................................................... 348 Expansion Valve................................................................................................................. 348 Blower Controller............................................................................................................... 348 Blower Motor Relay.............................................................................................................. 348 Compressor Clutch Relay......................................................................................................... 348 Air Mix Damper Actuator......................................................................................................... 348 Mode Selector Damper Actuator................................................................................................... 349 Evaporator Temperature Sensor................................................................................................... 349 Dual Pressure Switch............................................................................................................ 349 Sunlight Sensor................................................................................................................. 349 Blower and Intake Unit.............................................................................................................. 350 Automatic Air Conditioner....................................................................................................... 350 Functions of Major Components................................................................................................... 350 Refrigerant Compressor.............................................................................................................. 351 Function........................................................................................................................ 351 Specifications.................................................................................................................. 351 Condenser........................................................................................................................... 352 Function........................................................................................................................ 352 Specifications.................................................................................................................. 352 Receiver............................................................................................................................ 353 Function........................................................................................................................ 353 Specifications.................................................................................................................. 353 Air Conditioner Panel............................................................................................................... 354 Display Unit.................................................................................................................... 354 Switch Block.................................................................................................................... 355 Outline......................................................................................................................... 356 ELECTRICAL SYSTEM........................................................................................................................... 358 Machine Monitor System.................................................................................................................. 358 Outline............................................................................................................................. 358 Operator Mode....................................................................................................................... 358 Service Mode........................................................................................................................ 359 System Circuit Diagram.............................................................................................................. 360 Machine Monitor..................................................................................................................... 361 Speedometer Specification....................................................................................................... 361 Items Displayed on Monitor.......................................................................................................... 362 Machine Monitor Operation Switches...................................................................................................... 371 Setting Machine Monitor............................................................................................................. 372 Troubleshooting Function............................................................................................................ 372 Character Display Function.......................................................................................................... 373 Operator Mode Functions............................................................................................................. 374 Self-Check Screen (0th layer)................................................................................................... 374 Normal Screen (1st layer)....................................................................................................... 374 Failure Code Screen (1st layer)................................................................................................. 375 Display of Functions Available for the Operator (2nd layer or below)............................................................ 376 Service Mode Functions.............................................................................................................. 377 Procedure for Switching to Service Mode......................................................................................... 377 Service Mode Menu............................................................................................................... 378 Electrical System Failure History Display Function (ELECTRIC FAULT)............................................................. 379 Mechanical System Failure History Display Function (MACHINE FAULT).............................................................. 379 Real-Time Monitoring Function (REAL-TIME MONITOR)............................................................................... 379 Engine Reduced-Cylinder Function (CYLINDER CUT-OUT)............................................................................. 379 No Injection Cranking Function (NO INJECTION)................................................................................... 380 Adjustment Function (TUNING).................................................................................................... 380 Maintenance Monitoring Function (MAINTENANCE MONITOR)........................................................................... 380 Operating Information Display Function (OPERATION INFO)......................................................................... 380 Optional Device Selecting Function (OPTIONAL SELECT)............................................................................ 381 Machine Serial Number Input Function (MACHINE No. SET).......................................................................... 381 Model Selection Function (MACHINE).............................................................................................. 381 Initialize Function (INITIALIZE)................................................................................................ 381 Input and Output Signals............................................................................................................ 382 Transmission Controller System.......................................................................................................... 390 Gearshifting Control Function....................................................................................................... 390 Electronic Modulation Function.................................................................................................. 390 Gearshifting Display Function................................................................................................... 390 Automatic Gearshifting Function................................................................................................. 391 Auto-Shift Points Table......................................................................................................... 392 Auto-Shift Points............................................................................................................... 396 Shift Hold Function............................................................................................................. 398 Kickdown Function............................................................................................................... 398 Torque Converter Lockup Function................................................................................................ 399 Lockup Operating Points Table................................................................................................... 401 Forward..................................................................................................................... 401 Reverse..................................................................................................................... 403 Hunting Protection Function..................................................................................................... 405 Changing Shift Points........................................................................................................... 405 4th Gear Speed Derating Function................................................................................................ 405 Transmission Controller Protection Function..................................................................................... 406 Shift-Down Protection Function.................................................................................................. 407 Engine Overrun Prevention Function.............................................................................................. 407 Maximum Travel Speed Derating Function.......................................................................................... 408 Neutralizer Function............................................................................................................ 408 Engine Control Function......................................................................................................... 408 Economy Operation Pilot Lamp Function........................................................................................... 409 Cooling Fan Control Function........................................................................................................ 410 Fan Control..................................................................................................................... 411 Pump Protection Function........................................................................................................ 411 Control at Start of Engine...................................................................................................... 412 Fan Reverse Rotation Function................................................................................................... 413 Work Equipment Pump Swash Plate Control Function.................................................................................... 415 Engine Stop Prevention Control at Low Idle...................................................................................... 415 Pickup Auxiliary Function when Engine Speed is Low.............................................................................. 416 Transmission Cutoff Function........................................................................................................ 417 ECSS Function....................................................................................................................... 419 Outline......................................................................................................................... 419 Setting Method.................................................................................................................. 419 Operation....................................................................................................................... 420 Electric Emergency Steering Function................................................................................................ 421 Outline......................................................................................................................... 421 Setting method.................................................................................................................. 422 Self-Check Operation of Emergency Steering...................................................................................... 422 Directional Selector Switch Control Function........................................................................................ 423 Operation of Directional Selector Switch........................................................................................ 423 Safety Function at Start of Engine.............................................................................................. 424 Setting Method.................................................................................................................. 424 Multi-Function Mono Lever Function.................................................................................................. 425 Operation of FNR Switch......................................................................................................... 425 Safety Function at Start of Engine.............................................................................................. 426 Shift Hold Function............................................................................................................. 426 Kickdown Function............................................................................................................... 426 Setting Method.................................................................................................................. 426 Joystick Steerin Function........................................................................................................... 427 Operation of Directional Selector Switch........................................................................................ 428 Safety Function at Start of Engine.............................................................................................. 428 Shift-Up and Shift-Down Function................................................................................................ 429 Setting Method.................................................................................................................. 429 System Circuit Diagram.............................................................................................................. 430 Transmission Controller............................................................................................................. 431 Input and Output Signals........................................................................................................ 431 Work Equipment Controller System........................................................................................................ 433 Safety Function for Starting Engine................................................................................................. 433 Safety Function for Selecting Joystick Steering System.............................................................................. 433 Steering Speed Selecting Function................................................................................................... 434 Travel Speed-Sensitive Steering Function............................................................................................ 434 Adjusting Starting Current.......................................................................................................... 434 Setting Method...................................................................................................................... 434 Troubleshooting Function............................................................................................................ 434 System Circuit Diagram.............................................................................................................. 435 Work Equipment Controller........................................................................................................... 436 Input and Output Signals........................................................................................................ 436 ELECTRONIC TRANSMISSION CONTROL............................................................................................................. 438 Function................................................................................................................................ 439 Combination Switch...................................................................................................................... 440 Outline............................................................................................................................. 440 Function............................................................................................................................ 440 Operation........................................................................................................................... 441 KICKDOWN AND HOLD SWITCH.................................................................................................................... 442 Load Meter Cancel Switch and Load Meter Subtotal Switch................................................................................. 442 Function............................................................................................................................ 442 MULTI-FUNCTION KNOB......................................................................................................................... 443 Function................................................................................................................................ 443 Modification of Multi-Function Lever.................................................................................................... 444 Required............................................................................................................................ 444 Procedure........................................................................................................................... 445 JOYSTICK STEERING KNOB...................................................................................................................... 446 Function................................................................................................................................ 446 KOMTRAX TERMINAL SYSTEM..................................................................................................................... 447 KOMTRAX Terminal........................................................................................................................ 448 Model TC301......................................................................................................................... 448 Outline............................................................................................................................. 448 Input and Output Signals................................................................................................................ 449 ENGINE STARTING CIRCUIT..................................................................................................................... 450 Function................................................................................................................................ 451 Operation............................................................................................................................... 451 ENGINE STOPPING CIRCUIT..................................................................................................................... 452 Operation............................................................................................................................... 452 PREHEATING CIRCUIT.......................................................................................................................... 453 Outline................................................................................................................................. 453 Operation............................................................................................................................... 453 ENGINE POWER MODE SELECTOR CIRCUIT.......................................................................................................... 454 Function................................................................................................................................ 454 Operation............................................................................................................................... 454 ENGINE OUTPUT DERATING FUNCTION............................................................................................................. 455 AUTOMATIC WARM-UP FUNCTION.................................................................................................................. 455 PARKING BRAKE CIRCUIT....................................................................................................................... 456 Operation............................................................................................................................... 456 When ignition switch is turned OFF...................................................................................................... 456 When ignition switch is turned ON....................................................................................................... 456 When low oil pressure occurs on main brake (when emergency brake is applied)............................................................ 457 SENSORS..................................................................................................................................... 458 Speed Sensor............................................................................................................................ 458 Torque Converter Oil Temperature Sensor................................................................................................. 459 Hydraulic Oil Temperature Sensor........................................................................................................ 459 Transmission Oil Temperature Sensor..................................................................................................... 459 Brake Oil Temperature Sensor............................................................................................................ 459 Work Equipment Pump Oil Pressure Sensor................................................................................................. 460 Steering Pump Oil Pressure Sensor....................................................................................................... 460 Lift Cylinder Head Oil Pressure Sensor.................................................................................................. 460 Lift Cylinder Bottom Oil Pressure Sensor................................................................................................ 460 Transmission Cutoff Oil Pressure Sensor................................................................................................. 461 Coolant Lever Sensor.................................................................................................................... 462 Fuel Level Sensor....................................................................................................................... 463 Air Cleaner Clogging Sensor............................................................................................................. 464 Accelerator Pedal Sensor................................................................................................................ 465 Torque Values....................................................................................................................... 465 Function............................................................................................................................ 465 Accelerator signal.................................................................................................................. 465 Idle Validation Signal.............................................................................................................. 465 Water-In-Fuel Sensor.................................................................................................................... 466 Boom Kickout Proximity Switch........................................................................................................... 467 Bucket Positioner Proximity Switch...................................................................................................... 467 Lift Arm Potentiometer.................................................................................................................. 468 20 STANDARD VALUE TABLES........................................................................................................................ 469 STANDARD VALUE TABLES....................................................................................................................... 470 Service Value For Engine................................................................................................................ 470 Service Values For Chassis.............................................................................................................. 471 POSTURE AND PERFORMANCE MEASUREMENTS........................................................................................................ 473 Machine Posture......................................................................................................................... 478 30 TESTING AND ADJUSTING........................................................................................................................ 481 TOOLS....................................................................................................................................... 486 Tools for Testing, Adjusting, and Troubleshooting....................................................................................... 486 ENGINE COMPONENTS........................................................................................................................... 492 Engine Speed............................................................................................................................ 492 Measurement Conditions.............................................................................................................. 492 Measure Engine Speed (Low and High Idle)............................................................................................ 492 Measure Torque Converter Stall Speed................................................................................................ 492 Measure Hydraulic Stall Speed....................................................................................................... 493 Measure Torque Converter Stall and Hydraulic Stall (Full Stall) Speed............................................................... 493 Exhaust Gas Color....................................................................................................................... 494 Special Tools Required.............................................................................................................. 494 Measurement Condition............................................................................................................... 494 Using Handy Smoke Checker A1........................................................................................................ 494 Using Smoke Meter A2................................................................................................................ 494 Valve Clearance......................................................................................................................... 496 Special Tools Required.............................................................................................................. 496 Measurement Condition............................................................................................................... 496 Engine Compression...................................................................................................................... 498 Special Tools Required.............................................................................................................. 498 Measurement Condition............................................................................................................... 498 Blow-by Pressure........................................................................................................................ 502 Special Tools Required.............................................................................................................. 502 Measurement Conditions.............................................................................................................. 502 Engine Oil Pressure..................................................................................................................... 504 Special Tools Required.............................................................................................................. 504 Measurement Condition............................................................................................................... 504 Intake Air (Boost) Pressure............................................................................................................. 505 Special Tool Required............................................................................................................... 505 Measurement Condition............................................................................................................... 505 Determining a Defective Cylinder........................................................................................................ 507 Procedures.......................................................................................................................... 507 Determining Cylinder Group.......................................................................................................... 507 Isolating the Defective Cylinder.................................................................................................... 507 FUEL SYSTEM................................................................................................................................. 508 Handling Fuel System Equipment.......................................................................................................... 508 Precautions for Testing and Maintaining Fuel System................................................................................. 508 Precautions for Replacement of Fuel Filter Cartridge................................................................................ 508 Releasing Residual Pressure in Fuel System.............................................................................................. 508 Measuring Fuel Pressure................................................................................................................. 509 Special Tools Required.............................................................................................................. 509 Measuring Pressure in Fuel Low-pressure Circuit..................................................................................... 509 Measuring Pressure in Fuel Return Circuit........................................................................................... 510 Measuring Fuel Negative-Pressure Circuit Pressure................................................................................... 511 Fuel Delivery, Return, and Leak Rate.................................................................................................... 512 Special Tools Required.............................................................................................................. 512 Measuring Supply Pump Delivery...................................................................................................... 512 Measuring Return Rate from Supply Pump.............................................................................................. 513 Measuring Leakage from Pressure Limiter............................................................................................. 514 Measuring Return Rate from Injector................................................................................................. 515 Bleeding Air from Fuel Circuit.......................................................................................................... 516 Testing Leakage in Fuel System.......................................................................................................... 517 Handling Reduced Cylinder Mode Operation................................................................................................ 518 Handling No-Injection Cranking Operation................................................................................................ 518 Handling Controller Voltage Circuit..................................................................................................... 518 EXHAUST SYSTEM AND PIPING................................................................................................................... 519 Checking Muffler and Muffler Stack for Looseness and Damage............................................................................. 519 Checking Muffler Function............................................................................................................... 519 Checking Installed Condition of Cylinder Head and Manifolds............................................................................. 519 Checking Engine Piping for Damage and Looseness......................................................................................... 519 Air Intake and Exhaust Systems...................................................................................................... 519 Cooling System...................................................................................................................... 519 Fuel System......................................................................................................................... 519 BELTS....................................................................................................................................... 520 Air Conditioner Compressor Belt......................................................................................................... 520 Testing............................................................................................................................. 520 Adjusting........................................................................................................................... 520 Alternator Belt......................................................................................................................... 521 Replacing........................................................................................................................... 521 DIRECTIONAL LEVER........................................................................................................................... 523 Special Tool Required................................................................................................................... 523 Checking Operating Effort............................................................................................................... 523 Checking Stroke......................................................................................................................... 523 POWER TRAIN OIL PRESSURES................................................................................................................... 524 Oil Pressure Measuring Points And Gauges................................................................................................ 526 Special Tools Required.............................................................................................................. 526 Measuring Transmission Hydraulic Operating Pressures.................................................................................... 527 Transmission Main Relief Pressure................................................................................................... 527 Torque Converter Relief Pressure (Inlet)............................................................................................ 528 Torque Converter Outlet Pressure.................................................................................................... 529 Lockup Clutch Pressure (Lockup Clutch Specification)................................................................................ 530 F (Forward) Clutch Pressure......................................................................................................... 531 R (Reverse) Clutch Pressure......................................................................................................... 532 1st Clutch Pressure................................................................................................................. 533 2nd Clutch Pressure................................................................................................................. 534 3rd Clutch Pressure................................................................................................................. 535 9. After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition..... 535 4th Clutch Pressure................................................................................................................. 536 Lubrication Pressure................................................................................................................ 537 Adjusting Power Train Oil Pressures..................................................................................................... 538 Transmission Main Relief Valve...................................................................................................... 538 TRANSMISSION................................................................................................................................ 539 Speed Sensor............................................................................................................................ 539 Flushing Transmission System............................................................................................................ 540 Torque Converter, Transmission, and Hydraulic Circuit............................................................................... 540 Moving the Machine if Transmission Valve Fails.......................................................................................... 542 Moving the Machine.................................................................................................................. 543 Special Tool Required............................................................................................................... 543 STEERING SYSTEM............................................................................................................................. 546 Steering Stop Valve..................................................................................................................... 546 Testing............................................................................................................................. 546 Adjusting........................................................................................................................... 546 Steering Wheel.......................................................................................................................... 548 Special Tool Required............................................................................................................... 548 Measuring Play in Steering Wheel.................................................................................................... 548 Measuring Operating Effort of Steering Wheel........................................................................................ 548 Measuring Operating Time of Steering Wheel.......................................................................................... 549 Steering Oil Pressure................................................................................................................... 550 Special Tools Required.............................................................................................................. 550 Measuring Steering Relief Pressure.................................................................................................. 550 Measuring Steering Pilot Circuit Pressure........................................................................................... 551 Adjusting Steering Relief Pressure.................................................................................................. 552 Adjusting Steering Control Circuit Pressure......................................................................................... 552 Bleeding Air from Steering Circuit...................................................................................................... 553 Bleeding Air from Steering Pump..................................................................................................... 553 Bleeding Air from Steering Cylinder Circuit......................................................................................... 553 Steering Column Lock Lever.............................................................................................................. 554 HYDRAULIC DRIVE FAN......................................................................................................................... 556 Special Tools Required.................................................................................................................. 556 Measurement Conditions:................................................................................................................. 556 Measuring Fan Speed..................................................................................................................... 556 Measuring Fan Drive Oil Pressure........................................................................................................ 557 Bleeding Air from Hydraulic Drive Fan Circuit........................................................................................... 558 Special Tools Required.............................................................................................................. 558 Bleeding Air From Fan Pump.......................................................................................................... 558 Bleeding Air from Fan Motor Circuit................................................................................................. 559 WHEEL BRAKE SYSTEM.......................................................................................................................... 560 Measuring Brake Performance............................................................................................................. 561 Measurement Conditions.............................................................................................................. 561 Accumulator Charge...................................................................................................................... 562 Special Tools Required.............................................................................................................. 562 Measurement Conditions.............................................................................................................. 562 Measuring........................................................................................................................... 562 Adjusting........................................................................................................................... 563 Measuring Brake Oil Pressure............................................................................................................ 564 Special Tools Required.............................................................................................................. 564 Brake Test Kit S.................................................................................................................... 565 Testing Wear of Wheel Brake Disc........................................................................................................ 566 Special Tools Required.............................................................................................................. 566 Bleeding Air from Brake Circuit......................................................................................................... 567 Releasing Residual Pressure in Brake Accumulator Circuit................................................................................ 567 PARKING BRAKE SYSTEM........................................................................................................................ 568 Testing Parking Brake Performance....................................................................................................... 568 Measurement Conditions.............................................................................................................. 568 Measuring Parking Brake Oil Pressure................................................................................................ 570 Special Tools Required.......................................................................................................... 570 Measurement Conditions.......................................................................................................... 570 Checking Wear of Parking Brake Disc................................................................................................. 572 Special Tools Required.......................................................................................................... 572 Releasing Parking Brake Manually.................................................................................................... 573 WORK EQUIPMENT SYSTEM....................................................................................................................... 574 Work Equipment Control Levers........................................................................................................... 574 Special Tools Required.............................................................................................................. 574 Measurement Conditions.............................................................................................................. 574 Measuring Operating Effort.......................................................................................................... 574 Measuring Stroke.................................................................................................................... 574 PPC Oil Pressure........................................................................................................................ 575 Special Tools Required.............................................................................................................. 575 Measurement Condition............................................................................................................... 575 Measuring PPC Valve Basic Pressure.................................................................................................. 575 Measuring PPC Valve Output Pressure................................................................................................. 576 Replacing PPC Relief Valve.......................................................................................................... 577 Work Equipment Hydraulic Pressure....................................................................................................... 578 Special Tools Required.............................................................................................................. 578 Measurement Condition............................................................................................................... 578 Combination of Actuator And Valve................................................................................................... 578 Preparation Work.................................................................................................................... 578 Measuring Work Equipment Relief Pressure............................................................................................ 579 Measuring Unload Pressure........................................................................................................... 580 Measuring Work Equipment LS Differential Pressure................................................................................... 581 Adjusting Work Equipment Relief Pressure............................................................................................ 582 Adjusting LS Differential Pressure.................................................................................................. 582 Bleeding Air from Work Equipment Circuit................................................................................................ 583 From Work Equipment Pump (Piston Pump).............................................................................................. 583 From Hydraulic Cylinder............................................................................................................. 583 Releasing Residual Pressure in Work Equipment Circuit................................................................................... 584 From Circuit Between Hydraulic Cylinders and Control Valve.......................................................................... 584 From ECSS (Travel Damper) Circuit................................................................................................... 584 Work Equipment Positioners.............................................................................................................. 585 Bucket Positioner................................................................................................................... 585 Measurement Conditions.......................................................................................................... 585 Testing......................................................................................................................... 585 Adjusting Clearance............................................................................................................. 585 Adjusting Mounting Position (Stopping Position)................................................................................. 585 Boom Kickout........................................................................................................................ 586 Testing......................................................................................................................... 586 Adjusting....................................................................................................................... 586 Proximity Switch Operation Pilot Lamp................................................................................................... 587 ELECTRICAL SYSTEM TROUBLESHOOTING........................................................................................................... 588 Procedure for Testing Diodes............................................................................................................ 588 When Using Digital Type Circuit Tester.............................................................................................. 588 When Using Analog Type Circuit Tester............................................................................................... 589 Preparation for Troubleshooting Electric System......................................................................................... 590 Machine Monitor..................................................................................................................... 590 Transmission Controller............................................................................................................. 591 Work Equipment Controller (if equipped)............................................................................................. 592 KOMTRAX Terminal.................................................................................................................... 592 Sensors............................................................................................................................. 593 Boost Pressure and Temperature Sensor (BOOST PRESS & IMT)........................................................................... 593 Supply Pump IMV Solenoid (FUEL REGULATOR)........................................................................................... 593 Common Rail Pressure Sensor (FUEL RAIL PRESS)....................................................................................... 594 Engine Coolant Temperature Sensor (COOLANT TEMP).................................................................................... 594 KOMTRAX TERMINAL SYSTEM..................................................................................................................... 595 Terminal Installed at Plant Before Shipment............................................................................................. 595 Terminal Retrofitted Machine After Shipment............................................................................................. 595 Starting Operation...................................................................................................................... 595 Station Opening Check in Machine Side............................................................................................... 595 Application for the Start of Use.................................................................................................... 598 Request for Orbcomm Terminal Activation Form.................................................................................... 599 Komtrax Terminal Lamps.................................................................................................................. 600 Checking Antennas................................................................................................................... 601 Checking Terminal LED Displays...................................................................................................... 601 Display Contents of 7-segment And Dot For CPU....................................................................................... 602 MACHINE MONITOR SYSTEM...................................................................................................................... 603 Adjusting Machine Monitor............................................................................................................... 603 Adjusting for Replaced, Reassembled, or Added Sensor/Controller......................................................................... 604 Adjustment for User’s Needs............................................................................................................. 605 Special Functions of Machine Monitor (EMMS)............................................................................................. 606 Normal and Special Functions of Machine Monitor..................................................................................... 606 Functions and Flow of Service Mode...................................................................................................... 607 Operator Mode........................................................................................................................... 610 Service Meter/Clock Display Function (1)............................................................................................ 610 Load Meter Function (2) (if equipped)............................................................................................... 610 Odometer Display Function (3)....................................................................................................... 610 Maintenance Monitoring Function (4)................................................................................................. 611 1. Filter, oil replacement time display (automatic display)..................................................................... 611 2. Resetting replacement time (selection menu).................................................................................. 611 Telephone Number Input Function (5)................................................................................................. 611 Language Selection Function (6)..................................................................................................... 611 Monitor Brightness Adjustment Function (7).......................................................................................... 611 Time Adjustment Function (8)........................................................................................................ 612 Travel Speed/Engine Speed Display Selecting Function (9)............................................................................ 612 Travel Speed/Engine Speed Display/Non-Display Selecting Function (10)............................................................... 612 Action Code Display Function (11)................................................................................................... 613 Action Codes and Actions Alerted to Operator.................................................................................... 613 Failure Code Display Function (12).................................................................................................. 613 Service Mode............................................................................................................................ 615 Switching to Service Mode and Screen Display (1).................................................................................... 615 Electrical System Fault History Display Function (ELECTRIC FAULT) (2)............................................................... 617 Mechanical System Fault History Display Function (MACHINE FAULT) (3)................................................................ 619 Real-Time Monitoring Function (REAL-TIME MONITOR) (4)............................................................................... 620 Real-Time Monitoring Code Tables.................................................................................................... 623 Monitor Panel (Machine Monitor System).......................................................................................... 623 MON (Mechanical Monitor System)................................................................................................. 628 Transmission (Transmission Controller System)................................................................................... 630 TM: Detailed Data for Input and Output Signals (Transmission Controller System)................................................. 636 WRK (Work Equipment Controller Display)............................................................................................. 640 ENG (Engine Controller System)...................................................................................................... 648 Engine Reduced-Cylinder Function (CYLINDER CUT-OUT) (5)............................................................................. 650 No-Injection Cranking Function (6).................................................................................................. 651 Adjustment Function (TUNING) (7).................................................................................................... 652 Adjustment Function............................................................................................................. 652 Adjustment of Transmission ECMV Current (7-1)................................................................................... 653 Setting of Transmission Initial Learning (7-2).................................................................................. 657 Adjustment of Transmission L Mode Gearshift Point (7-3)......................................................................... 660 Adjustment of Lift Arm Angle Sensor (Raise) (for EPC lever) (7-4)............................................................... 663 Adjustment of Lift Arm Raise Lever and Variations in the Dead Zone of EPC (7-5)................................................. 663 Adjustment of Lift Arm Lower (Float) Lever and Variations in the Dead Zone of EPC (7-6)......................................... 663 Adjustment of Bucket Tilt Lever and Variations in the Dead Zone of EPC (7-7).................................................... 663 Adjustment of Bucket Dump EPC Starting Current (7-8)............................................................................ 664 Adjustment of 3-spool Valve EPC Cylinder Extraction Lever and Variations in the Dead Zone of EPC (7-9).......................... 664 Adjustment of 3-spool valve EPC Cylinder Retraction Lever and Variations in the Dead Zone of EPC (7-10)......................... 664 Adjustment of Joystick Steering Right Lever and Variations at EPC Starting Point (7-11)......................................... 664 Adjustment of Joystick Steering Left Lever and Variations at EPC Starting Point (7-12).......................................... 664 Modification of Lift Arm Lever Pattern (7-13)................................................................................... 664 Modification of Bucket Lever Pattern (7-14)..................................................................................... 664 Adjustment of Lift Arm Lower Stop Modulation (7-15)............................................................................. 664 Adjustment of Pump Cutoff Pressure in Lift Arm Raise (7-16)..................................................................... 664 Adjustment of Lift Arm Angle Sensor (Raise) (7-17).............................................................................. 664 Adjustment of Lift Arm Angle Sensor (Lower) (7-18).............................................................................. 665 Adjustment of 2-stage Low Idle Throttle Position (7-19)......................................................................... 667 Adjustment of Interval of Fan Automatic Reverse Operation (Automatic Reverse Fan) (7-20)........................................ 667 Adjustment of Continuance of Fan Automatic Reverse Operation (Automatic Reverse Fan) (7-21)..................................... 668 Maintenance Monitoring Function (8)................................................................................................. 669 Changing Maintenance Interval Time (8-1)........................................................................................ 669 Selecting Enabling or Disabling Timer by Item (8-2)............................................................................. 671 Changing Set Default Value (8-3)................................................................................................ 672 Selecting between Timer Stop for All Items and Enable by Item (8-4)............................................................. 673 Operating Information Display Function (OPERATION INFO) (9)......................................................................... 675 Selecting Menu.................................................................................................................. 675 Optional Device Selecting Function (10)............................................................................................. 678 Optional Component Setting table................................................................................................ 678 Change or Settlement for BOOM TYPE OPTION SELECT (10-1)......................................................................... 680 Option Setting/Not Setting Selection (10-2)..................................................................................... 681 Setting Tire Deflection Option (10-3)........................................................................................... 681 Storing Option Selection (10-4)................................................................................................. 681 Machine Serial Number Input Function (11)........................................................................................... 682 Model Select Function (12).......................................................................................................... 682 Implementing the Model Change................................................................................................... 682 Storing Model Change (12-2)..................................................................................................... 683 Initialize Function (13)............................................................................................................ 683 PM-CLINIC INSPECTION TABLE.................................................................................................................. 684 40 TROUBLESHOOTING.............................................................................................................................. 689 POINTS TO REMEMBER WHEN TROUBLESHOOTING..................................................................................................... 705 SEQUENCE OF EVENTS IN TROUBLESHOOTING....................................................................................................... 707 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE................................................................................................... 708 Precautions when Handling Electrical Equipment.......................................................................................... 708 Handling Electronic Control Unit........................................................................................................ 713 Points to Remember when Troubleshooting Electrical Circuits............................................................................. 714 ELECTRIC WIRE CODE.......................................................................................................................... 715 Classification by Thickness............................................................................................................. 715 Classification by Color and Code........................................................................................................ 715 How to Read Electric Wire Code.......................................................................................................... 716 Type, Symbol, and Material.......................................................................................................... 716 Dimensions.......................................................................................................................... 717 HANDLING HYDRAULIC EQUIPMENT................................................................................................................ 718 CHECKS BEFORE TROUBLESHOOTING............................................................................................................... 720 Categories and Method of Using Troubleshooting Charts................................................................................... 721 Troubleshooting Individual Electrical Circuits.......................................................................................... 722 Chart Use........................................................................................................................... 724 Chart Tips.......................................................................................................................... 724 Troubleshooting Individual Hydraulic Circuits........................................................................................... 725 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.................................................................................................. 727 X-Type Connectors....................................................................................................................... 727 SWP-Type Connectors..................................................................................................................... 729 M-Type Connectors....................................................................................................................... 731 S-Type Connectors....................................................................................................................... 733 MIC-Type Connectors..................................................................................................................... 735 AMP040-Type Connectors.................................................................................................................. 737 AMP070-Type Connectors.................................................................................................................. 739 AMP Connector........................................................................................................................... 741 L-Type Connector........................................................................................................................ 741 PA-Type Connector....................................................................................................................... 742 Bendix (MS) Connector................................................................................................................... 742 KES1 (Automobile) Connectors............................................................................................................ 743 F-Type Connector........................................................................................................................ 744 Connectors for Relay (Socket-Type)...................................................................................................... 745 HD30 Series Connectors.................................................................................................................. 746 DT Series Connectors.................................................................................................................... 752 DTM Series Connectors................................................................................................................... 754 DTHD Series Connectors.................................................................................................................. 754 DTP Series Connectors................................................................................................................... 755 DRC26 Series Connectors................................................................................................................. 756 DRC12, 16 Series Connectors............................................................................................................. 758 AMP Connectors for Pump Controller (CH700).............................................................................................. 759 BOSCH Connectors for Engine............................................................................................................. 760 SUMITOMO Connectors for Engine.......................................................................................................... 761 CANNON Connector for Engine............................................................................................................. 762 AMP Connectors for Engine............................................................................................................... 763 FRAMATOME Connectors for Engine......................................................................................................... 764 PACKARD Connectors for Engine........................................................................................................... 766 DT Series Connectors for Engine......................................................................................................... 767 T-BRANCH BOX and T-BRANCH ADAPTER TABLE..................................................................................................... 768 MODE CHART.................................................................................................................................. 773 INFORMATION CONTAINED IN TESTING PROCEDURES................................................................................................. 776 TROUBLESHOOTING BY FAILURE CODE............................................................................................................. 778 Failure Code Table...................................................................................................................... 778 FUSE BOX AND SLOW-BLOW FUSES................................................................................................................ 789 Connection Table........................................................................................................................ 789 Fuse Box 1.......................................................................................................................... 789 Fuse Box 2.......................................................................................................................... 790 Slow-Blow Fuses..................................................................................................................... 790 FAILURE CODES............................................................................................................................... 792 1500L0.................................................................................................................................. 793 TORQFLOW Transmission: Double Meshing............................................................................................... 793 15SAL1.................................................................................................................................. 794 ECMV F Clutch: When Command Current is OFF, Fill Signal is ON....................................................................... 794 15SALH.................................................................................................................................. 796 ECMV F Clutch: When Command Current is ON, Fill Signal is OFF....................................................................... 796 15SBL1.................................................................................................................................. 798 ECMV R Clutch: When Command Current is OFF, Fill Signal is ON....................................................................... 798 15SBLH.................................................................................................................................. 800 ECMV R Clutch: When Command Current is ON, Fill Signal is OFF....................................................................... 800 15SEL1.................................................................................................................................. 802 ECMV 1st Clutch: When Command Current is OFF, Fill Signal is ON..................................................................... 802 15SELH.................................................................................................................................. 804 ECMV 1st Clutch: When Command Current is ON, Fill Signal is OFF..................................................................... 804 15SFL1.................................................................................................................................. 806 ECMV 2nd Clutch: When Command Current is OFF, FIll Signal is ON..................................................................... 806 15SFLH.................................................................................................................................. 808 ECMV 2nd Clutch: When Command Current is ON, Fill Signal is OFF..................................................................... 808 15SGL1.................................................................................................................................. 810 ECMV 3rd Clutch: When Command Current is OFF, Fill Signal is ON..................................................................... 810 15GLH................................................................................................................................... 812 ECMV 3rd Clutch: When Command Current is ON, Fill Signal is OFF..................................................................... 812 15SHL1.................................................................................................................................. 814 ECMV 4th Clutch: When Command Current is OFF, Fill Signal is ON..................................................................... 814 15SHLH.................................................................................................................................. 816 ECMV 4th Clutch: When Command Current is ON, Fill Signal is OFF..................................................................... 816 2F00MA.................................................................................................................................. 818 Parking Brake: Malfunction.......................................................................................................... 818 2G43ZG.................................................................................................................................. 820 Rear Accumulator: Low Oil Pressure.................................................................................................. 820 44K0L4.................................................................................................................................. 822 Bucket Positioner: ON/OFF Signals Disagree.......................................................................................... 822 AA1ANX.................................................................................................................................. 826 Air Cleaner: Clogging............................................................................................................... 826 AB00L6.................................................................................................................................. 828 Alternator: Signal Disagrees with Operating State of Engine......................................................................... 828 AB00MA.................................................................................................................................. 830 Alternator: Malfunction............................................................................................................. 830 B@BAZG.................................................................................................................................. 832 Engine: Rotation Derating by Low Engine Oil Pressure................................................................................ 832 B@BAZK.................................................................................................................................. 833 Engine Oil: Low Level............................................................................................................... 833 B@BCNS.................................................................................................................................. 834 Engine Coolant: Overheating......................................................................................................... 834 B@BCZK.................................................................................................................................. 836 Engine Coolant: Low Level........................................................................................................... 836 B@BEBF.................................................................................................................................. 838 Water in Fuel Error................................................................................................................. 838 B@C7NS.................................................................................................................................. 840 Brake Oil: Overheating.............................................................................................................. 840 b@CENS.................................................................................................................................. 842 Torque Converter Oil: Overheating................................................................................................... 842 B@CENS.................................................................................................................................. 844 Torque Converter Oil: Overheating................................................................................................... 844 B@HANS.................................................................................................................................. 846 Hydraulic Oil: Overheating.......................................................................................................... 846 CA111................................................................................................................................... 848 Abnormality in Engine Controller.................................................................................................... 848 CA115................................................................................................................................... 849 Engine Ne or Bkup Speed Sensor Error................................................................................................ 849 CA122................................................................................................................................... 850 Charge Pressure Sensor High Error................................................................................................... 850 CA123................................................................................................................................... 852 Charge Pressure Sensor Low Error.................................................................................................... 852 CA131................................................................................................................................... 854 Throttle Sensor High Error.......................................................................................................... 854 CA132................................................................................................................................... 856 Throttle Sensor Low Error........................................................................................................... 856 CA144................................................................................................................................... 858 Coolant Temperature Sensor High Error............................................................................................... 858 CA145................................................................................................................................... 860 Coolant Temperature Sensor Low Error................................................................................................ 860 CA153................................................................................................................................... 862 Charge Temperature Sensor High Error................................................................................................ 862 CA154................................................................................................................................... 864 Charge Temperature Sensor Low Error................................................................................................. 864 CA155................................................................................................................................... 866 Derating of Speed by Abnormally High Charge Temperature............................................................................. 866 CA187................................................................................................................................... 868 Sensor Power Supply 2 Low Error..................................................................................................... 868 CA221................................................................................................................................... 870 Atmospheric Pressure Sensor High Error.............................................................................................. 870 CA222................................................................................................................................... 872 Atmospheric Pressure Sensor Low Error............................................................................................... 872 CA227................................................................................................................................... 874 Sensor Power Supply 2 High Error.................................................................................................... 874 CA234................................................................................................................................... 876 Engine Overspeed.................................................................................................................... 876 CA238................................................................................................................................... 877 Ne Speed Sensor Power Supply Error.................................................................................................. 877 CA271................................................................................................................................... 878 IMV/PCV1 Short Circuit.............................................................................................................. 878 CA272................................................................................................................................... 880 IMV/PCV1 Disconnection.............................................................................................................. 880 CA322................................................................................................................................... 882 Injector #1 Open/Short Error........................................................................................................ 882 CA323................................................................................................................................... 884 Injector #5 Open/Short Error........................................................................................................ 884 CA324................................................................................................................................... 886 Injector #3 Open/Short Error........................................................................................................ 886 CA325................................................................................................................................... 888 Injector #6 Open/Short Error........................................................................................................ 888 CA331................................................................................................................................... 890 Injector #2 Open/Short Error........................................................................................................ 890 CA332................................................................................................................................... 892 Injector #4 Open/Short Error........................................................................................................ 892 CA342................................................................................................................................... 894 Calibration Code Inconsistency...................................................................................................... 894 CA351................................................................................................................................... 896 Injectors Drive Circuit Error....................................................................................................... 896 CA352................................................................................................................................... 898 Sensor Power Supply 1 Low Error..................................................................................................... 898 CA386................................................................................................................................... 900 Sensor Power Supply 1 High Error.................................................................................................... 900 CA428................................................................................................................................... 902 Abnormally High Level in Water Sensor............................................................................................... 902 CA429................................................................................................................................... 904 Abnormally Low Level in Water Sensor................................................................................................ 904 CA431................................................................................................................................... 906 Idle Validation Switch Error........................................................................................................ 906 CA432................................................................................................................................... 910 Idle Validation Action Error........................................................................................................ 910 CA435................................................................................................................................... 912 Engine Oil Pressure Switch Error.................................................................................................... 912 CA441................................................................................................................................... 914 Battery Voltage Low Error........................................................................................................... 914 CA442................................................................................................................................... 918 Battery Voltage High Error.......................................................................................................... 918 CA449................................................................................................................................... 920 Common Rail Pressure High Error 2................................................................................................... 920 CA451................................................................................................................................... 924 Common Rail Pressure Sensor High Error.............................................................................................. 924 CA452................................................................................................................................... 926 Common Rail Pressure Sensor Low Error............................................................................................... 926 CA488................................................................................................................................... 928 Derating of Torque by Abnormally High Charge Temperature............................................................................ 928 CA553................................................................................................................................... 929 Common Rail Pressure High Error 1................................................................................................... 929 CA559................................................................................................................................... 930 Supply Pump Pressure Very Low Error 1............................................................................................... 930 CA689................................................................................................................................... 932 Engine Ne Speed Sensor Error........................................................................................................ 932 CA731................................................................................................................................... 934 Engine Bkup Speed Sensor Phase Error................................................................................................ 934 CA757................................................................................................................................... 935 All Continuous Data Lost Error...................................................................................................... 935 CA778................................................................................................................................... 938 Engine Bkup Speed Sensor Error...................................................................................................... 938 CA1633.................................................................................................................................. 940 KOMNET Datalink Timeout Error....................................................................................................... 940 CA2185.................................................................................................................................. 942 Throttle Sensor Power Supply Voltage High Error..................................................................................... 942 CA2186.................................................................................................................................. 943 Throttle Sensor Power Supply Voltage Low Error...................................................................................... 943 CA2249.................................................................................................................................. 944 Supply Pump Pressure Very Low Error 2............................................................................................... 944 CA2311.................................................................................................................................. 946 Abnormality in IMV Solenoid......................................................................................................... 946 CA2555.................................................................................................................................. 948 Intake Heater Relay Disconnection Error............................................................................................. 948 CA2556.................................................................................................................................. 950 Intake Heater Relay Short Circuit Error............................................................................................. 950 D150KA.................................................................................................................................. 952 Emergency Steering Relay: Disconnection............................................................................................. 952 D150KB.................................................................................................................................. 954 Emergency Steering Relay: Short Circuit............................................................................................. 954 D150KY.................................................................................................................................. 956 Emergency Steering Relay: Short Circuit with Power Supply Line...................................................................... 956 D160KA.................................................................................................................................. 958 Backup Lamp Relay: Disconnection.................................................................................................... 958 D160KB.................................................................................................................................. 960 Backup Lamp Relay: Short Circuit.................................................................................................... 960 D191KA.................................................................................................................................. 962 Joystick Steering Neutral Safety Relay: Disconnection............................................................................... 962 D191KB.................................................................................................................................. 964 Joystick Steering Neutral Safety Relay: Short Circuit............................................................................... 964 D191KY.................................................................................................................................. 966 Joystick Steering Neutral Safety Relay: Short Circuit with Power Supply Line........................................................ 966 D192KA.................................................................................................................................. 968 ECSS Solenoid: Disconnection........................................................................................................ 968 D192KB.................................................................................................................................. 970 ECSS Solenoid: Short Circuit........................................................................................................ 970 D192KY.................................................................................................................................. 972 ECSS Solenoid Relay: Short Circuit with Power Supply Line........................................................................... 972 D193KA.................................................................................................................................. 974 Joystick Steering Solenoid Cut Relay: Disconnection................................................................................. 974 D193KB.................................................................................................................................. 976 Joystick Steering Solenoid Cut Relay: Short Circuit................................................................................. 976 D193KY.................................................................................................................................. 978 Joystick Steering Solenoid Cut Relay: Short Circuit with Power Supply Line.......................................................... 978 D5ZHKA.................................................................................................................................. 980 Terminal C Signal: Disconnection.................................................................................................... 980 D5ZHKB.................................................................................................................................. 984 Terminal C Signal: Short Circuit.................................................................................................... 984 D5ZHKZ.................................................................................................................................. 988 Terminal C Signal: Disconnection or Short Circuit................................................................................... 988 D5ZHL6.................................................................................................................................. 992 Terminal C Signal: Signal Does Not Match Engine Running or Stopped State............................................................ 992 DA80L4.................................................................................................................................. 996 Auto-Grease Controller: ON/OFF Signals Disagree..................................................................................... 996 DAF3KK.................................................................................................................................. 998 Machine Monitor: Low Source Voltage (input)......................................................................................... 998 DAF5KP..................................................................................................................................1000 Machine Monitor: Low Output Voltage.................................................................................................1000 DAFRKR..................................................................................................................................1004 Machine Monitor: CAN Defective Communication........................................................................................1004 DAQ0KK..................................................................................................................................1008 Transmission Controller: Low Source Voltage.........................................................................................1008 DAQ0KT..................................................................................................................................1010 Transmission Controller: Abnormality in Controller..................................................................................1010 DAQ2KK..................................................................................................................................1012 Transmission Controller Load Power Supply Line: Low Source Voltage (input)..........................................................1012 DAQ9KQ..................................................................................................................................1014 Transmission Controller: Disagreement of Model Selection Signals....................................................................1014 DAQRKR..................................................................................................................................1016 CAN Communication with Transmission Controller: Defective Communication.............................................................1016 DAQRMA..................................................................................................................................1019 Transmission Controller Option Setting: Malfunction.................................................................................1019 DB2RKR..................................................................................................................................1020 CAN Communication with Engine Controller: Defective Communication...................................................................1020 DB90KK..................................................................................................................................1024 Work Equipment Controller: Low Source Voltage (input)...............................................................................1024 DB90KT..................................................................................................................................1026 Work Equipment Controller: Abnormality in Controller................................................................................1026 DB92KK..................................................................................................................................1028 Work Equipment Controller Load Power Supply Line: Low Source Voltage (input)........................................................1028 DD95KX..................................................................................................................................1030 Work Equipment Controller Power Supply Output: Out-of-Input Signal Range............................................................1030 DB99KQ..................................................................................................................................1033 Work Equipment Controller: Disagreement in Model Selection Signals..................................................................1033 DB9RKR..................................................................................................................................1034 CAB Communication with Work Equipment Controller: Defective Communication...........................................................1034 DB9RMA..................................................................................................................................1037 Work Equipment Controller Option Setting: Malfunction...............................................................................1037 DB9RMC..................................................................................................................................1038 CAN Communication: Defective Operation..............................................................................................1038 DD15LD..................................................................................................................................1042 Switch (Panel Switch 1 n): Switch is Pressed for Long Time..........................................................................1042 DD16LD..................................................................................................................................1044 Switch (Panel Switch 2 ‡): Switch is Pressed for Long Time..........................................................................1044 DD17LD..................................................................................................................................1046 Switch (Panel Switch 3 <): Switch is Pressed for Long Time..........................................................................1046 DD18LD..................................................................................................................................1048 Switch (Panel Switch 4 >): Switch is Pressed for Long Time..........................................................................1048 DD1ALD..................................................................................................................................1050 Remote Positioner Raise/Lower Set Switch (raise): Switch is Pressed for Long Time...................................................1050 DD1BLD..................................................................................................................................1052 Remote Positioner Raise/Lower Set Switch (lower): Switch is Pressed for Long Time...................................................1052 DD1CLD..................................................................................................................................1054 Load Meter Subtotal Switch: Switch is Pressed for Long Time.........................................................................1054 DD1FLD..................................................................................................................................1056 Load Meter Mode Selector Switch (A/B): Switch is Pressed for Long Time..............................................................1056 DD1GLD..................................................................................................................................1058 Load Meter Mode Selector Switch (+/-): Switch is Pressed for Long Time..............................................................1058 DD1HLD..................................................................................................................................1060 Load Meter Display Selector Switch: Switch is Pressed for Long Time.................................................................1060 DD1NLD..................................................................................................................................1062 Fan Reverse Switch: Switch is Pressed for Long Time.................................................................................1062 DD1NL4..................................................................................................................................1064 Fan Automatic Reverse Switch: Switch is Pressed for Long Time.......................................................................1064 DDB6L4..................................................................................................................................1066 Parking Brake Switch (Neutralizer): ON/OFF Signals Disagree.........................................................................1066 DDE5MA..................................................................................................................................1070 Emergency Steering Drive Switch: Malfunction........................................................................................1070 DDK3KA..................................................................................................................................1072 Right FNR Switch: Disconnection.....................................................................................................1072 DDK4KA..................................................................................................................................1075 Joystick Steering FNR Switch: Disconnection.........................................................................................1075 DDK5L4..................................................................................................................................1078 Joystick Steering Shift UP/DOWN Switch: ON/OFF Signals Disagree.....................................................................1078 DDK6KA..................................................................................................................................1080 FNR Lever Switch: Disconnection.....................................................................................................1080 DDK6KB..................................................................................................................................1083 FNR Lever Switch: Short Circuit.....................................................................................................1083 DDS5KA..................................................................................................................................1086 Steering Pressure Switch: Disconnected..............................................................................................1086 DDS5KB..................................................................................................................................1088 Steering Pressure Switch: Grounded..................................................................................................1088 DDT0L4..................................................................................................................................1090 Shift Mode Selector Switch: ON/OFF Signals Disagree.................................................................................1090 DDT4LD..................................................................................................................................1092 Transmission Cutoff Set Switch: Switch is Pressed for Long Time.....................................................................1092 DDW9LD..................................................................................................................................1094 Kickdown Switch: Switch is Pressed for Long Time....................................................................................1094 DDWLLD..................................................................................................................................1096 Hold Switch: Switch is Pressed Down for Long Time...................................................................................1096 DDY0LD..................................................................................................................................1098 Load Meter Cancel Switch: Switch is Pressed for Long Time...........................................................................1098 DF10KA..................................................................................................................................1100 Transmission Shift Lever Switch: Disconnected.......................................................................................1100 DF10KB..................................................................................................................................1104 Transmission Shift Lever Switch: Short Circuit......................................................................................1104 DGF1KA..................................................................................................................................1108 Transmission Oil Temperature Sensor: Disconnected...................................................................................1108 DGF1KB..................................................................................................................................1110 Transmission Oil Temperature Sensor: Short Circuit..................................................................................1110 DGH2KX..................................................................................................................................1112 Hydraulic Oil Temperature Sensor: Out-of-Input Signal Range.........................................................................1112 DGR2KA..................................................................................................................................1114 Rear Brake Oil Temperature Sensor: Disconnected.....................................................................................1114 DGR2KX..................................................................................................................................1116 Rear Brake Oil Pressure Sensor: Out-of-Input Signal Range...........................................................................1116 DGT1KX..................................................................................................................................1118 Torque Converter Oil Temperature Sensor: Out-of-Input Signal Range..................................................................1118 DH21KA..................................................................................................................................1120 Loader Pump Pressure Sensor: Disconnection..........................................................................................1120 DH21KB..................................................................................................................................1122 Loader Pump Pressure Sensor: Power Supply Line Short................................................................................1122 DHPCKX..................................................................................................................................1124 Lift Arm Cylinder Bottom Pressure Sensor: Out-of-Input Signal Range.................................................................1124 DHPDKX..................................................................................................................................1126 Lift Arm Cylinder Head Pressure Sensor: Out-of-Input Signal Range...................................................................1126 DHT1KX..................................................................................................................................1128 Transmission Cutoff Pressure Sensor: Out-of-Input Signal............................................................................1128 DHT8KA..................................................................................................................................1130 Steering Pump Pressure Sensor: Disconnection........................................................................................1130 DHT8KB..................................................................................................................................1132 Steering Pump Pressure Sensor: Short Circuit........................................................................................1132 DK59KA..................................................................................................................................1134 Lift Arm EPC Lever Potentiometer (Main): Disconnection..............................................................................1134 DK59KY..................................................................................................................................1137 Lift Arm EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line.......................................................1137 DK59L8..................................................................................................................................1141 Lift Arm EPC Lever Potentiometer (Main): Analog Signals Disagree....................................................................1141 DK5AKA..................................................................................................................................1145 Lift Arm EPC Lever Potentiometer (Sub): Disconnection...............................................................................1145 DK5AKY..................................................................................................................................1148 Lift Arm EPC Lever Potentiometer (Sub): Short Circuit with Power Supply LIne........................................................1148 DK5BKA..................................................................................................................................1151 Bucket EPC Lever Potentiometer (Main): Disconnection................................................................................1151 DK5BKY..................................................................................................................................1154 Bucket EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line.........................................................1154 DK5BL8..................................................................................................................................1157 Bucket EPC Lever Potentiometer (Main): Analog Signals Disagree......................................................................1157 DK5CKA..................................................................................................................................1160 Bucket EPC Lever Potentiometer (Sub): Disconnection.................................................................................1160 DK5CKY..................................................................................................................................1163 Bucket EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line..........................................................1163 DK5FKA..................................................................................................................................1166 Joystick Steering EPC Lever Potentiometer (Main): Disconnection.....................................................................1166 DK5FKY..................................................................................................................................1169 Joystick Steering EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line..............................................1169 DK5GKA..................................................................................................................................1172 Joystick Steering EPC Lever Potentiometer (Sub): Disconnection......................................................................1172 DK5GKY..................................................................................................................................1175 Joystick Steering EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line...............................................1175 DK5FL8..................................................................................................................................1178 Joystick Steering EPC Lever Potentiometer (Main): Analog Signals Disagree...........................................................1178 DKA0KA..................................................................................................................................1181 Lift Arm Angle Sensor: Disconnection................................................................................................1181 DKA0KY..................................................................................................................................1185 Lift Arm Angle Sensor: Short Circuit with Power Supply Line.........................................................................1185 DKA0L0..................................................................................................................................1187 Lift Arm Angle Sensor: Double Meshing...............................................................................................1187 DLT3KA..................................................................................................................................1189 Transmission Output Shaft Speed Sensor: Disconnection...............................................................................1189 DLT3LC..................................................................................................................................1191 Transmission Output Shaft Speed Sensor: Out-of-Input Signal Range...................................................................1191 DT20KB..................................................................................................................................1193 Transmission Cutoff Indicator Lamp: Short Circuit...................................................................................1193 DUM1KB..................................................................................................................................1195 Remote Positioner Raise Set Indicator Lamp: Short Circuit...........................................................................1195 DUM2KB..................................................................................................................................1197 Remote Positioner Lower Set Indicator Lamp: Short Circuit...........................................................................1197 DV00KB..................................................................................................................................1199 Alarm Buzzer: Short Circuit.........................................................................................................1199 DW4PKA..................................................................................................................................1201 Lift Arm Raise EPC Solenoid: Disconnection..........................................................................................1201 DW4PKB..................................................................................................................................1203 Lift Arm Raise EPC Solenoid: Short Circuit..........................................................................................1203 DW4PKY..................................................................................................................................1205 Lift Arm Raise EPC Solenoid: Short Circuit with Power Supply Line...................................................................1205 DW4QKA..................................................................................................................................1207 Lift Arm Lower EPC Solenoid: Disconnection..........................................................................................1207 DW4QKB..................................................................................................................................1209 Lift Arm Lower EPC Solenoid: Short Circuit..........................................................................................1209 DW4QKY..................................................................................................................................1211 Lift Arm Lower EPC Solenoid: Short Circuit with Power Supply Line...................................................................1211 DW4RKA..................................................................................................................................1213 Bucket Tilt EPC Solenoid: Disconnection.............................................................................................1213 DW4RKB..................................................................................................................................1215 Bucket Tilt EPC Solenoid: Short Circuit.............................................................................................1215 DW4RKY..................................................................................................................................1217 Bucket Tilt EPC Solenoid: Short Circuit with Power Supply Line......................................................................1217 DW4SKA..................................................................................................................................1219 Buck Dump EPC Solenoid: Disconnection...............................................................................................1219 DW4SKB..................................................................................................................................1221 Bucket Dump EPC Solenoid: Short Circuit.............................................................................................1221 DW4SKY..................................................................................................................................1223 Bucket Dump EPC Solenoid: Short Circuit with Power Supply Line......................................................................1223 DW7BKA..................................................................................................................................1225 Fan Reverse Solenoid: Disconnection.................................................................................................1225 DW7BKB..................................................................................................................................1227 Fan Reverse Solenoid: Short Circuit.................................................................................................1227 DW7BKY..................................................................................................................................1229 Fan Reverse Solenoid: Short Circuit with Power Supply Line..........................................................................1229 DWM1KA..................................................................................................................................1231 Work Equipment Neutral Lock Solenoid: Disconnection.................................................................................1231 DWM1KB..................................................................................................................................1233 Work Equipment Neutral Lock Solenoid: Short Circuit.................................................................................1233 DWM1KY..................................................................................................................................1235 Work Equipment Neutral Lock Solenoid: Short Circuit with Power Supply Line..........................................................1235 DWN6KA..................................................................................................................................1237 Lift Arm Raise Magnet Detent Solenoid: Disconnection................................................................................1237 DWN6KB..................................................................................................................................1239 Lift Arm Raise Magnet Detent Solenoid: Short Circuit................................................................................1239 DWN6KY..................................................................................................................................1241 Lift Arm Raise Magnet Detent Solenoid: Short Circuit with Power Supply Line.........................................................1241 DWN7KA..................................................................................................................................1243 Lift Arm Float Magnet Detent Solenoid: Disconnection................................................................................1243 DWN7KB..................................................................................................................................1245 Lift Arm Float Magnet Detent Solenoid: Short Circuit................................................................................1245 DWN7KY..................................................................................................................................1247 Lift Arm Float Magnet Detent Solenoid: Short Circuit with Power Supply Line.........................................................1247 DWN8KA..................................................................................................................................1249 Bucket Tilt Magnet Detent Solenoid: Disconnection...................................................................................1249 DWN8KB..................................................................................................................................1251 Bucket Tilt Magnet Detent Solenoid: Short Circuit...................................................................................1251 DWN8KY..................................................................................................................................1253 Bucket Tilt Magnet Detent Solenoid: Shorted with the Power Source...................................................................1253 DX16KA..................................................................................................................................1255 Fan Pump EPC Solenoid: Disconnection................................................................................................1255 DX16KB..................................................................................................................................1257 Fan Pump EPC Solenoid: Short Circuit................................................................................................1257 DX16KY..................................................................................................................................1259 Fan Pump EPC Solenoid: Short Circuit with Power Supply Line.........................................................................1259 DXA1KA..................................................................................................................................1261 Loader Pump EPC Solenoid: Disconnection.............................................................................................1261 DXH1KA..................................................................................................................................1263 Lockup ECMV Solenoid: Disconnection.................................................................................................1263 DXH1KB..................................................................................................................................1265 Lockup ECMV Solenoid: Short Circuit.................................................................................................1265 DXH1KY..................................................................................................................................1267 Lockup ECMV Solenoid: Short Circuit with Power Supply Line..........................................................................1267 DXH4KA..................................................................................................................................1269 1st Clutch ECMV Solenoid: Disconnection.............................................................................................1269 DXH4KB..................................................................................................................................1271 1st Clutch ECMV Solenoid: Short Circuit.............................................................................................1271 DXH4KY..................................................................................................................................1273 1st Clutch ECMV Solenoid: Short Circuit with Power Supply Line......................................................................1273 DXH5KA..................................................................................................................................1275 2nd Clutch ECMV Solenoid: Disconnection.............................................................................................1275 DXH5KB..................................................................................................................................1277 2nd Clutch ECMV Solenoid: Short Circuit.............................................................................................1277 DXH5KY..................................................................................................................................1279 2nd Clutch ECMV Solenoid: Short Circuit with Power Supply Line......................................................................1279 DXH6KA..................................................................................................................................1281 3rd Clutch ECMV Solenoid: Disconnection.............................................................................................1281 DXH6KB..................................................................................................................................1283 3rd Clutch ECMV Solenoid: Short Circuit.............................................................................................1283 DXH6KY..................................................................................................................................1285 3rd Clutch ECMV Solenoid: Short Circuit with Power Supply Line......................................................................1285 DXH7KA..................................................................................................................................1287 R Clutch ECMV Solenoid: Disconnection...............................................................................................1287 DXH7KB..................................................................................................................................1289 R Clutch ECMV Solenoid: Short Circuit...............................................................................................1289 DXH7KY..................................................................................................................................1291 R Clutch ECMV Solenoid: Short Circuit with Power Supply Line........................................................................1291 DXH8KA..................................................................................................................................1293 F Clutch ECMV Solenoid: Disconnection...............................................................................................1293 DXH8KB..................................................................................................................................1295 F Clutch ECMV Solenoid: Short Circuit...............................................................................................1295 DXH8KY..................................................................................................................................1297 F Clutch ECMV Solenoid: Short Circuit with Power Supply Line........................................................................1297 DXHHKA..................................................................................................................................1299 4th Clutch ECMV Solenoid: Disconnection.............................................................................................1299 DXHHKB..................................................................................................................................1301 4th Clutch ECMV Solenoid: Short Circuit.............................................................................................1301 DXHHKY..................................................................................................................................1303 4th Clutch ECMV Solenoid: Short Circuit with Power Supply Line......................................................................1303 DXHLKA..................................................................................................................................1305 Joystick Steering Right EPC Solenoid: Disconnection.................................................................................1305 DXHLKB..................................................................................................................................1307 Joystick Steering Right EPC Solenoid: Short Circuit.................................................................................1307 DXHLKY..................................................................................................................................1309 Joystick Steering Right EPC Solenoid: Short Circuit with Power Supply Line..........................................................1309 DXHMKA..................................................................................................................................1311 Joystick Steering Left EPC Solenoid: Disconnection..................................................................................1311 DXHMKB..................................................................................................................................1313 Joystick Steering Left EPC Solenoid: Short Circuit..................................................................................1313 DXHMKY..................................................................................................................................1315 Joystick Steering Left EPC Solenoid: Short Circuit with Power Supply Line...........................................................1315 DY30MA..................................................................................................................................1317 Motor-Driven Emergency Steering Pump Failure (during Operation of machine)..........................................................1317 DY30MC..................................................................................................................................1320 Motor-Driven Emergency Steering Pump Failure (Malfunction in Manual Mode)...........................................................1320 TROUBLESHOOTING: E-MODE.....................................................................................................................1323 E-1.....................................................................................................................................1325 Engine Does Not Start...............................................................................................................1325 E-2.....................................................................................................................................1331 Wiper Does Not Operate..............................................................................................................1331 E-3.....................................................................................................................................1335 Windshield Washer Does Not Operate..................................................................................................1335 E-4.....................................................................................................................................1339 Headlamp, Clearance Lamp, Tail Lamp, and License Lamp Do Not Light Up or Go Off.....................................................1339 E-5.....................................................................................................................................1347 Working Lamp Does Not Light Up or Go Off............................................................................................1347 E-6.....................................................................................................................................1353 Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off..........................................................................1353 E-7.....................................................................................................................................1360 Brake Lamp Does Not Light or It Keeps Lighting Up...................................................................................1360 E-8.....................................................................................................................................1363 Backup Lamp Does Not Light or It Keeps Lighting Up..................................................................................1363 E-9.....................................................................................................................................1366 Backup Buzzer Does Not Sound or It Keeps Sounding...................................................................................1366 E-10....................................................................................................................................1369 Horn Does Not Sound or It Keeps Sounding............................................................................................1369 E-11....................................................................................................................................1372 Alarm Buzzer Does Not Sound or It Keeps Sounding....................................................................................1372 E-12....................................................................................................................................1374 Air Conditioner Does Not Operate or Stop............................................................................................1374 E-13....................................................................................................................................1378 KOMTRAX System Does Not Work Properly...............................................................................................1378 Indicator Lamps of KOMTRAX Terminal.............................................................................................1380 E-14....................................................................................................................................1382 When Kickdown Switch is Turned On, Kickdown Operation Does Not Start................................................................1382 E-15....................................................................................................................................1384 When Hold Switch is Pressed, Holding Operation Does Not Start.......................................................................1384 E-16....................................................................................................................................1386 Transmission Kept in Neutral or Brake Drags when Directional Lever is Operated While Parking Brake is Applied.......................1386 E-17....................................................................................................................................1388 Transmission Cutoff Mode Cannot Be Set or Reset.....................................................................................1388 E-18....................................................................................................................................1390 Transmission Cutoff Set Cannot be Reset.............................................................................................1390 E-19....................................................................................................................................1392 FN Switch Mode Cannot Be Set or Reset...............................................................................................1392 E-20....................................................................................................................................1394 Fan Reverse Function Cannot Be Used or Reset........................................................................................1394 E-21....................................................................................................................................1396 Discharge from Loader Pump Does Not Rise from Minimum Level.........................................................................1396 E-22....................................................................................................................................1398 ECSS Function Cannot Be Used or Reset...............................................................................................1398 E-23....................................................................................................................................1400 When Parking Brake is Turned On, Parking Brake Indicator Lamp Does Not Light Up.....................................................1400 E-24....................................................................................................................................1404 When Emergency Brake Operates, Brake Oil Pressure Caution Lamp Does Not Operate.....................................................1404 E-25....................................................................................................................................1406 Air Cleaner Clogging Indicator Lamp Does Not Light Up...............................................................................1406 E-26....................................................................................................................................1408 Radiator Coolant Level Caution Lamp Does Not Light Up...............................................................................1408 E-27....................................................................................................................................1410 Hydraulic Oil Temperature Gauge Does Not Rise and Hydraulic Oil Temperature Caution Lamp Does Not Light Up..........................1410 E-28....................................................................................................................................1412 Torque Converter Oil Temperature Gauge Does Not Rise and Torque Converter Oil Temperature Caution Lamp Does Not Light Up............1412 E-29....................................................................................................................................1414 Steering Oil Pressure Caution Lamp Does Not Light Up................................................................................1414 E-30....................................................................................................................................1416 Abnormality in Switch (n) (Panel Switch 1) Input....................................................................................1416 E-31....................................................................................................................................1418 Abnormality in Switch (‡) (Panel Switch 2) Input....................................................................................1418 E-32....................................................................................................................................1420 Abnormality in Switch (<) (Panel Switch 3) Input....................................................................................1420 E-33....................................................................................................................................1422 Abnormality in Switch (>) (Panel Switch 4) Input....................................................................................1422 Troubleshooting Electrical System.......................................................................................................1323 Information in Troubleshooting Table................................................................................................1323 TROUBLESHOOTING: H-MODE.....................................................................................................................1424 H-1.....................................................................................................................................1430 Machine Does Not Start..............................................................................................................1430 H-2.....................................................................................................................................1432 Torque Converter Lockup is Not Switched OFF (Engine Stalls).........................................................................1432 H-3.....................................................................................................................................1433 Torque Converter Lockup is Not Switched ON..........................................................................................1433 H-4.....................................................................................................................................1434 Travel Speed is Slow, Thrusting Force is Weak, Uphill Traveling Power is Weak, Gear is Not Shifted..................................1434 H-5.....................................................................................................................................1438 Large Shocks When Starting and Shifting Gears.......................................................................................1438 H-6.....................................................................................................................................1442 Large Time Lag When Starting and Shifting Gear......................................................................................1442 H-7.....................................................................................................................................1446 Torque Converter Oil Temperature is High............................................................................................1446 H-8.....................................................................................................................................1447 Steering Does Not Turn..............................................................................................................1447 H-9.....................................................................................................................................1448 Steering Does Not Turn (Joystick Steering, if equipped).............................................................................1448 H-10....................................................................................................................................1449 Steering Response is Poor...........................................................................................................1449 H-11....................................................................................................................................1450 Steering, Turning Response is Poor (Joystick Steering, if Equipped).................................................................1450 H-12....................................................................................................................................1451 Steering is Heavy...................................................................................................................1451 H-13....................................................................................................................................1452 When Machine Turns, It Shakes or Jerks..............................................................................................1452 H-14....................................................................................................................................1453 When Machine Turns, It Shakes or Jerks (Joystick Steering, if Equipped).............................................................1453 H-15....................................................................................................................................1454 Wheel Brake Does Not Work or Does Not Work Well.....................................................................................1454 H-16....................................................................................................................................1455 Wheel Brake is Not Released or It Drags.............................................................................................1455 H-17....................................................................................................................................1456 Parking Brake Does Not Work or Does Not Work Well...................................................................................1456 H-18....................................................................................................................................1457 Parking Brake is Not Released or It Drags...........................................................................................1457 H-19....................................................................................................................................1458 Lift Arm Does Not Rise..............................................................................................................1458 H-20....................................................................................................................................1459 Lift Arm Speed is Low or Rising Force is Insufficient...............................................................................1459 H-21....................................................................................................................................1460 When Rising, Lift Arm Starts to Move Slowly at a Specific Height....................................................................1460 H-22....................................................................................................................................1460 Lift Arm Cylinder Cannot Hold Down Bucket (Bucket Floats)...........................................................................1460 H-23....................................................................................................................................1460 Hydraulic Drifts of the Lift Arm Are Large..........................................................................................1460 H-24....................................................................................................................................1461 Lift Arm Wobbles During Operation...................................................................................................1461 H-25....................................................................................................................................1462 Bucket Does Not Tilt Back...........................................................................................................1462 H-26....................................................................................................................................1463 Bucket Speed is Low or Tilting-Back Force Is Insufficient...........................................................................1463 H-27....................................................................................................................................1464 Bucket Starts to Operate Slowly in the Midst of Tilting Back........................................................................1464 H-28....................................................................................................................................1464 Bucket Cylinder Cannot Hold Down the Bucket.........................................................................................1464 H-29....................................................................................................................................1464 Hydraulic Drifts of the Bucket Are Large............................................................................................1464 H-30....................................................................................................................................1465 Bucket Wobbles During Travel with Load..............................................................................................1465 H-31....................................................................................................................................1466 Lift Arm and Bucket Control Levers Do Not Move Smoothly and Are Heavy...............................................................1466 H-32....................................................................................................................................1467 During Operation of Machine, Engine Speed Drops Remarkably or Engine Stalls.........................................................1467 H-33....................................................................................................................................1467 Large Shocks When Work Equipment Starts and Stops...................................................................................1467 H-34....................................................................................................................................1467 When Work Equipment Circuit is Relieved Singly, Other Work Equipment Moves..........................................................1467 Troubleshooting Hydraulic and Mechanical Systems........................................................................................1424 Using Troubleshooting Chart.........................................................................................................1424 Failure Codes and Causes Table..........................................................................................................1426 50 DISASSEMBLY AND ASSEMBLY.....................................................................................................................1469 HOW TO READ THIS MANUAL.....................................................................................................................1473 Removal and Installation of Assemblies..................................................................................................1473 Disassembly and Assembly of Assemblies..................................................................................................1475 COATING MATERIALS LIST......................................................................................................................1477 SPECIAL TOOLS LIST..........................................................................................................................1480 SKETCHES OF SPECIAL TOOLS...................................................................................................................1483 CONNECTOR REPAIR PROCEDURES.................................................................................................................1489 Stripping Insulation....................................................................................................................1489 Wire Inspection.........................................................................................................................1489 Contact Terminal Removal (HD30 Type)....................................................................................................1490 Crimping Contact Terminal (HD30 Type)...................................................................................................1491 Insertion Of Contact Terminal (HD30 Type)...............................................................................................1492 Contact Terminal Removal (DT Type)......................................................................................................1493 Crimping Contact Terminal (DT Type).....................................................................................................1494 Insertion Of Contact Terminal (DT Type).................................................................................................1495 ENGINE AND COOLING SYSTEM...................................................................................................................1496 Alternator..............................................................................................................................1496 Crankshaft..............................................................................................................................1496 Camshaft................................................................................................................................1496 Engine Front Seal.......................................................................................................................1496 Engine Oil Cooler.......................................................................................................................1496 Engine Rear Seal........................................................................................................................1496 Starting Motor..........................................................................................................................1496 Thermostat..............................................................................................................................1496 Turbocharger............................................................................................................................1496 Water Pump..............................................................................................................................1496 Cylinder Head...........................................................................................................................1497 Removal.............................................................................................................................1497 Installation........................................................................................................................1503 Engine Hood.............................................................................................................................1510 Removal.............................................................................................................................1510 Installation........................................................................................................................1512 Radiator................................................................................................................................1513 Removal.............................................................................................................................1513 Installation........................................................................................................................1514 Air Aftercooler.........................................................................................................................1515 Removal.............................................................................................................................1515 Installation........................................................................................................................1516 Hydraulic Oil Cooler....................................................................................................................1517 Removal.............................................................................................................................1517 Installation........................................................................................................................1518 Engine..................................................................................................................................1519 Removal.............................................................................................................................1519 Installation........................................................................................................................1524 Cooling Fan and Fan Motor...............................................................................................................1526 Removal.............................................................................................................................1526 Installation........................................................................................................................1529 FUEL SUPPLY SYSTEM..........................................................................................................................1530 Fuel Supply Pump........................................................................................................................1530 Removal.............................................................................................................................1530 Installation........................................................................................................................1531 Fuel Injector...........................................................................................................................1532 Removal.............................................................................................................................1532 Installation........................................................................................................................1535 Fuel Tank...............................................................................................................................1540 Removal.............................................................................................................................1540 Installation........................................................................................................................1542 POWER TRAIN.................................................................................................................................1543 Torque Converter and Transmission Assembly..............................................................................................1543 Removal.............................................................................................................................1543 Installation........................................................................................................................1550 Torque Converter (Standard Specification)...............................................................................................1551 Disassembly.........................................................................................................................1551 Assembly............................................................................................................................1554 Torque Converter (Lockup Specification).................................................................................................1557 Disassembly.........................................................................................................................1557 Assembly............................................................................................................................1560 Transmission............................................................................................................................1565 Disassembly.........................................................................................................................1565 Assembly............................................................................................................................1575 Clutch Pack.............................................................................................................................1586 Forward and Reverse Clutch Pack: Disassembly........................................................................................1586 1st and 4th Clutch Pack: Disassembly................................................................................................1590 2nd and 3rd Gear Clutch Pack: Disassembly...........................................................................................1593 Forward and Reverse Clutch Pack: Assembly...........................................................................................1599 1st and 4th Clutch Pack: Assembly...................................................................................................1603 2nd and 3rd Clutch Pack: Assembly...................................................................................................1607 Parking Brake...........................................................................................................................1612 Disassembly.........................................................................................................................1612 Assembly............................................................................................................................1617 Front Axle..............................................................................................................................1624 Removal.............................................................................................................................1624 Installation........................................................................................................................1625 Rear Axle...............................................................................................................................1626 Removal.............................................................................................................................1626 Installation........................................................................................................................1629 Axle Housing............................................................................................................................1631 Disassembly.........................................................................................................................1631 Assembly............................................................................................................................1636 Differential Assembly...................................................................................................................1643 Disassembly.........................................................................................................................1643 Assembly............................................................................................................................1652 STEERING SYSTEM.............................................................................................................................1668 Steering Valve Assembly.................................................................................................................1668 Removal.............................................................................................................................1668 Installation........................................................................................................................1670 BRAKING SYSTEM..............................................................................................................................1671 Parking Brake Discs and Plates..........................................................................................................1671 Removal.............................................................................................................................1671 Installation........................................................................................................................1673 UNDERCARRAGE AND FRAME......................................................................................................................1674 Center Hinge Pin........................................................................................................................1674 Removal.............................................................................................................................1674 Installation........................................................................................................................1679 Counterweight...........................................................................................................................1684 Removal.............................................................................................................................1684 Installation........................................................................................................................1686 HYDRAULIC SYSTEM............................................................................................................................1687 Work Equipment Control Valve............................................................................................................1687 Removal.............................................................................................................................1687 Installation........................................................................................................................1689 Power Train Pump and Work Equipment Pump Assembly.......................................................................................1690 Removal.............................................................................................................................1690 Installation........................................................................................................................1690 Steering Pump And Cooling Fan Pump Assembly.............................................................................................1691 Removal.............................................................................................................................1691 Installation........................................................................................................................1692 Hydraulic Tank..........................................................................................................................1693 Removal.............................................................................................................................1693 Installation........................................................................................................................1696 WORK EQUIPMENT..............................................................................................................................1697 Work Equipment Assembly.................................................................................................................1697 Removal.............................................................................................................................1697 Installation........................................................................................................................1700 Hydraulic Cylinder......................................................................................................................1702 Disassembly.........................................................................................................................1702 Assembly............................................................................................................................1706 CAB AND ATTACHMENTS.........................................................................................................................1711 Cab and Floor Frame.....................................................................................................................1711 Removal.............................................................................................................................1711 Installation........................................................................................................................1714 Cab Glass (Stuck Glass).................................................................................................................1715 Removal.............................................................................................................................1715 Installation........................................................................................................................1716 Operator Seat Assembly (Standard Specification) (ISRING HAUSEN).........................................................................1724 Disassembly.........................................................................................................................1724 Assembly............................................................................................................................1731 Operator Seat Assembly (GRAMMER)........................................................................................................1736 Upper Seat..........................................................................................................................1736 Suspension..........................................................................................................................1744 AIR CONDITIONER UNIT ASSEMBLY...............................................................................................................1772 Removal.................................................................................................................................1772 Installation............................................................................................................................1776 ELECTRICAL SYSTEM...........................................................................................................................1777 Engine Controller Assembly..............................................................................................................1777 Removal.............................................................................................................................1777 Installation........................................................................................................................1777 90 DIAGRAMS AND SCHEMATICS......................................................................................................................1779 AUTOMATIC GREASING..........................................................................................................................1781 Auto-Grease Circuit Diagram.............................................................................................................1781 HYDRAULIC SYSTEM............................................................................................................................1782 Power Train Hydraulic Circuit Diagram...................................................................................................1782 Without Lockup Clutch...............................................................................................................1782 With Lockup Clutch..................................................................................................................1782 Hydraulic Circuit Diagram...............................................................................................................1783 ELECTRICAL SYSTEM...........................................................................................................................1784 Machine Monitor System Circuit Diagram..................................................................................................1784 Transmission Controller System Circuit Diagram..........................................................................................1785 Work Equipment Controller System Diagram................................................................................................1786 Work Equipment Controller System Electrical Circuit Diagram.............................................................................1787 Electrical Circuit Diagram (1/14).......................................................................................................1788 Electrical Circuit Diagram (2/14).......................................................................................................1789 Electrical Circuit Diagram (3/14).......................................................................................................1790 Electrical Circuit Diagram (4/14).......................................................................................................1791 Electrical Circuit Diagram (5/14).......................................................................................................1792 Electrical Circuit Diagram (6/14).......................................................................................................1793 Electrical Circuit Diagram (7/14).......................................................................................................1794 Electrical Circuit Diagram (8/14).......................................................................................................1795 Electrical Circuit Diagram (9/14).......................................................................................................1796 Electrical Circuit Diagram (10/14)......................................................................................................1797 Electrical Circuit Diagram (11/14)......................................................................................................1798 Electrical Circuit Diagram (12/14)......................................................................................................1799 Electrical Circuit Diagram (13/14)......................................................................................................1800 Electrical Circuit Diagram (14/14)......................................................................................................1801 Connector List and Stereogram...........................................................................................................1802 Chassis.............................................................................................................................1802 Engine and Transmission.............................................................................................................1803 Operator's Compartment..............................................................................................................1804
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