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Komatsu WA380-6 WHEEL LOADER Service Repair Manual – PDF Download
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- Komatsu WA380-6 WHEEL LOADER Service Repair Manual
- SERIAL NUMBERS WA380-6 A53001 and up
- PUBLICATION NUMBER:CEBM017403
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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 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
CEBM017403 - WA380-6 sn A53001 and UP................................................................................................... 0 CONTENTS............................................................................................................................ 2 REVISED PAGES....................................................................................................................... 3 SAFETY.............................................................................................................................. 17 Safety Notice................................................................................................................... 17 IMPORTANT SAFETY NOTICE..................................................................................................... 17 General Precautions......................................................................................................... 17 Preparations for Work....................................................................................................... 18 Precautions During Work..................................................................................................... 18 GENERAL............................................................................................................................. 19 HOW TO READ THE SHOP MANUAL......................................................................................................... 20 Volumes......................................................................................................................... 20 Distribution and Updating....................................................................................................... 20 Filing Method................................................................................................................... 20 Revised Edition Mark............................................................................................................ 20 Revisions....................................................................................................................... 20 Symbols......................................................................................................................... 20 HOISTING INSTRUCTIONS............................................................................................................... 21 Hoisting........................................................................................................................ 21 Making Signs.................................................................................................................... 21 Precautions..................................................................................................................... 21 Precautions for Sling Work.................................................................................................. 21 Precautions for Using Mobile Crane.......................................................................................... 22 Precautions for Using Overhead Hoist Crane.................................................................................. 22 Selecting Wire Ropes............................................................................................................ 23 AIR CONDITIONER CIRCUITS............................................................................................................ 24 Precautions for Handling Hoses and Tubes........................................................................................ 24 Disconnecting Hoses and Tubes............................................................................................... 24 Connecting Hoses and Tubes.................................................................................................. 24 MAINTENANCE STANDARD TERMS.......................................................................................................... 25 Handling Connectors Used for Engines............................................................................................ 27 Slide Lock Type............................................................................................................. 27 Pull Lock Type.............................................................................................................. 28 Push Lock Type.............................................................................................................. 28 Turn-housing Type (Round Green Connector)................................................................................... 30 PRECAUTIONS FOR OPERATIONS.......................................................................................................... 31 Precautions when Carrying Out Removal Work...................................................................................... 31 Precautions when Carrying Out Installation Work................................................................................. 32 Precautions when Completing the Operation....................................................................................... 33 PUSH-PULL COUPLER................................................................................................................... 34 Type 1.......................................................................................................................... 34 Disconnection............................................................................................................... 34 Connection.................................................................................................................. 34 Type 2.......................................................................................................................... 35 Disconnection............................................................................................................... 35 Connection.................................................................................................................. 35 Type 3.......................................................................................................................... 36 Disconnection............................................................................................................... 36 Connection.................................................................................................................. 36 COATING MATERIALS................................................................................................................... 37 STANDARD TIGHTENING TORQUE.......................................................................................................... 39 Standard Tightening Tables...................................................................................................... 39 For Bolts and Nuts.......................................................................................................... 39 For Split Flange Bolts...................................................................................................... 40 For O-Ring Boss Piping Joints............................................................................................... 40 For O-Ring Boss Plugs....................................................................................................... 41 For Hoses (Taper-Seal Type and Face-Seal Type).............................................................................. 41 For Face Seal Joints........................................................................................................ 42 For 102, 107, and 114 Engine Series (Bolts and Nuts)........................................................................ 42 For 102, 107, and 114 Engine Series (Eye Joints)............................................................................ 42 For 102, 107, and 114 Engine Series (Taper Screws).......................................................................... 43 CONVERSION TABLES................................................................................................................... 44 Method of Using the Conversion Table............................................................................................ 44 01 GENERAL.............................................................................................................................. 51 SPECIFICATIONS...................................................................................................................... 53 Dimension Drawing............................................................................................................... 53 Specification Tables............................................................................................................ 55 WEIGHT TABLE........................................................................................................................ 60 FUEL, COOLANT, AND LUBRICANTS....................................................................................................... 62 10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD.......................................................................................... 65 ENGINE AND COOLING SYSTEM........................................................................................................... 70 Engine and Transmission Mounting................................................................................................ 70 Cooling System.................................................................................................................. 72 Cooling Fan Pump................................................................................................................ 74 Servo Valve..................................................................................................................... 79 Cooling Fan Motor System........................................................................................................ 82 Hydraulic Motor................................................................................................................. 85 Suction Valve................................................................................................................... 88 Reversible Valve................................................................................................................ 86 Safety Valve.................................................................................................................... 87 POWER TRAIN SYSTEM.................................................................................................................. 89 Drive Line Components........................................................................................................... 89 System Diagram.................................................................................................................. 90 Drive Shaft System.............................................................................................................. 92 Power Train Piping System....................................................................................................... 93 Torque Converter................................................................................................................ 94 Without Lockup Clutch....................................................................................................... 94 Power Transmitting Route.................................................................................................... 96 Oil Flow.................................................................................................................... 96 With Lockup Clutch.......................................................................................................... 97 Torque Flow..................................................................................................................... 100 When Lockup Clutch Is Disengaged............................................................................................ 100 When Lockup Clutch Is Engaged............................................................................................... 100 Oil Flow.................................................................................................................... 101 Transmission.................................................................................................................... 102 With Lockup Clutch.......................................................................................................... 102 Forward and Reverse Clutches.................................................................................................... 112 Without Lockup Clutch....................................................................................................... 112 With Lockup Clutch.......................................................................................................... 113 1st and 4th Clutches........................................................................................................ 114 2nd and 3rd Clutches........................................................................................................ 115 Operation of Clutch Pack.................................................................................................... 116 Transmission Torque Flow Route.................................................................................................. 118 Forward 1st Gear Speed...................................................................................................... 118 Forward 2nd Gear Speed...................................................................................................... 120 Forward 3rd Gear Speed...................................................................................................... 122 Forward 4th Gear Speed...................................................................................................... 124 Reverse 1st Gear Speed...................................................................................................... 126 Flow Control Valve.............................................................................................................. 128 Valve Assembly.............................................................................................................. 130 ECMV System..................................................................................................................... 132 For R, 1st, and 2nd Clutches................................................................................................ 132 For F, 3rd, 4th, and Lockup Clutches........................................................................................ 134 ECMV For Gear Speed Clutch.................................................................................................. 136 ECMV for Lockup Clutch...................................................................................................... 139 Main and Torque Converter Relief Valve System................................................................................... 142 Outline..................................................................................................................... 144 Operation................................................................................................................... 144 DRIVE AXLE SYSTEM................................................................................................................... 145 Front Axle Assembly............................................................................................................. 145 Rear Axle Assembly.............................................................................................................. 146 Front Differential.............................................................................................................. 148 Rear Differential............................................................................................................... 150 Limited Slip Differential....................................................................................................... 153 Front Axle Carrier.............................................................................................................. 154 Rear Axle Carrier............................................................................................................... 156 Final Drive..................................................................................................................... 160 STEERING SYSTEM..................................................................................................................... 162 Steering Piping Diagram......................................................................................................... 162 Steering Column................................................................................................................. 163 Steering Pump................................................................................................................... 164 Pump Unit................................................................................................................... 166 Servo Valve................................................................................................................. 171 LS Valve.................................................................................................................... 174 PC Valve.................................................................................................................... 174 Steering Valve.................................................................................................................. 178 Operation of Flow Amplifier................................................................................................. 182 Operation of Flow Control Spool............................................................................................. 184 Operation of Steering Valve................................................................................................. 186 Steering Relief Valve....................................................................................................... 189 Overload Relief Valve....................................................................................................... 190 Relief Valve................................................................................................................ 191 Orbitrol Valve.................................................................................................................. 192 Stop Valve...................................................................................................................... 196 Steering Relief Valve........................................................................................................... 197 Steering Cylinder............................................................................................................... 198 Emergency Steering Motor........................................................................................................ 200 Emergency Steering Pump (If Equipped)........................................................................................... 201 Joystick Steering Lever Linkage................................................................................................. 202 Steering Electric Lever......................................................................................................... 203 Joystick EPC Valve.............................................................................................................. 204 Multi-Function Lever and Joystick Lever (Modification).......................................................................... 205 SERVICE BRAKING SYSTEM.............................................................................................................. 207 Brake Piping Diagram............................................................................................................ 207 Charge Valve.................................................................................................................... 208 Brake Valve..................................................................................................................... 216 Accumulator (for Brakes)........................................................................................................ 221 Front Brake..................................................................................................................... 222 Rear Brake...................................................................................................................... 224 PARKING BRAKE SYSTEM................................................................................................................ 226 Brake Control................................................................................................................... 226 Parking Brake Unit.............................................................................................................. 228 Parking Brake Solenoid Valve.................................................................................................... 230 Emergency Parking Brake Release Valve........................................................................................... 232 UNDERCARRIAGE AND FRAME............................................................................................................. 233 Axle Mounting and Center Hinge Pin.............................................................................................. 233 Tires........................................................................................................................... 238 HYDRAULIC SYSTEM.................................................................................................................... 240 Piping Diagram.................................................................................................................. 240 Work Equipment Control Lever System............................................................................................. 243 Multi-Function Mono-Lever Type.................................................................................................. 244 Hydraulic Tank.................................................................................................................. 246 Tank Vent System............................................................................................................ 247 Power Train Pump................................................................................................................ 248 Work Equipment Pump............................................................................................................. 250 Pump Unit................................................................................................................... 252 Servo Valve................................................................................................................. 254 LS Valve.................................................................................................................... 260 PC valve.................................................................................................................... 261 Work Equipment Control Valve.................................................................................................... 264 4-Spool Valve............................................................................................................... 266 CLSS............................................................................................................................ 282 Outline of CLSS............................................................................................................. 282 Basic Principle............................................................................................................. 283 Pressure Compensation Control............................................................................................... 284 Function and Operation of Each Valve............................................................................................ 285 Unload Valve................................................................................................................ 286 Work Equipment Valve (Supply of LS Pressure)................................................................................ 289 LS Bypass Plug.............................................................................................................. 291 Pressure Compensation Valve................................................................................................. 292 Lift Arm Regeneration Circuit............................................................................................... 296 Variable Lift Check Valve................................................................................................... 298 ECSS Control Valve.......................................................................................................... 299 Accumulator Charge Valve.................................................................................................... 302 PPC Valve................................................................................................................... 306 Stabilizer Valve............................................................................................................ 311 Work Equipment PPC Cutoff Solenoid Valve.................................................................................... 316 Accumulator (for PPC Circuit)................................................................................................... 318 Accumulator (for ECSS).......................................................................................................... 319 WORK EQUIPMENT...................................................................................................................... 320 Work Equipment Linkage.......................................................................................................... 320 Bucket.......................................................................................................................... 322 Bucket Positioner and Boom Kickout.............................................................................................. 324 Bucket Positioner........................................................................................................... 325 Boom Kick-out............................................................................................................... 325 Proximity Switch............................................................................................................ 326 Work Equipment Cylinders........................................................................................................ 332 Lift Cylinder............................................................................................................... 332 Bucket Cylinder............................................................................................................. 332 CAB ENVIRONMENT..................................................................................................................... 333 ROPS Cab........................................................................................................................ 333 Air Conditioner................................................................................................................. 334 Air Conditioner Piping Diagram.............................................................................................. 334 Refrigerant Circuit Diagram................................................................................................. 336 Air Conditioner Unit........................................................................................................ 337 Blower and Intake Unit...................................................................................................... 340 Refrigerant Compressor...................................................................................................... 341 Condenser................................................................................................................... 342 Receiver.................................................................................................................... 343 Air Conditioner Panel....................................................................................................... 344 ELECTRICAL SYSTEM................................................................................................................... 348 Machine Monitor System.......................................................................................................... 348 System Circuit Diagram...................................................................................................... 350 Machine Monitor............................................................................................................. 351 Items Displayed on Monitor.................................................................................................. 352 Machine Monitor Operation Switches.............................................................................................. 361 Setting Machine Monitor..................................................................................................... 362 Troubleshooting Function.................................................................................................... 362 Character Display Function.................................................................................................. 363 Operator Mode Functions..................................................................................................... 364 Service Mode Functions...................................................................................................... 367 Input and Output Signals.................................................................................................... 372 Transmission Controller System.................................................................................................. 380 Gearshifting Control Function............................................................................................... 380 Cooling Fan Control Function................................................................................................ 399 Work Equipment Pump Swash Plate Control Function............................................................................ 404 Transmission Cutoff Function................................................................................................ 406 ECSS Function............................................................................................................... 408 Electric Emergency Steering Function........................................................................................ 410 Directional Selector Switch Control Function................................................................................ 412 Multi-Function Mono Lever Function.......................................................................................... 414 Joystick Steering Function.................................................................................................. 416 System Circuit Diagram...................................................................................................... 419 Transmission Controller..................................................................................................... 420 Work Equipment Controller System................................................................................................ 422 System Circuit Diagram...................................................................................................... 424 Work Equipment Controller................................................................................................... 426 ELECTRONIC TRANSMISSION CONTROL..................................................................................................... 428 Combination Switch.............................................................................................................. 430 KICKDOWN AND HOLD SWITCH............................................................................................................ 432 Load Meter Cancel Switch and Load Meter Subtotal Switch......................................................................... 432 MULTI-FUNCTION KNOB................................................................................................................. 433 Modification of Multi-Function Lever............................................................................................ 434 JOYSTICK STEERING KNOB.............................................................................................................. 436 KOMTRAX TERMINAL SYSTEM............................................................................................................. 437 KOMTRAX Terminal................................................................................................................ 438 Input and Output Signals........................................................................................................ 439 ENGINE STARTING CIRCUIT............................................................................................................. 440 ENGINE STOPPING CIRCUIT............................................................................................................. 442 PREHEATING CIRCUIT.................................................................................................................. 443 ENGINE POWER MODE SELECTOR CIRCUIT.................................................................................................. 444 ENGINE OUTPUT DERATING FUNCTION..................................................................................................... 445 AUTOMATIC WARM-UP FUNCTION.......................................................................................................... 445 PARKING BRAKE CIRCUIT............................................................................................................... 446 SENSORS............................................................................................................................. 448 Speed Sensor.................................................................................................................... 448 Torque Converter Oil Temperature Sensor......................................................................................... 449 Hydraulic Oil Temperature Sensor................................................................................................ 449 Transmission Oil Temperature Sensor............................................................................................. 449 Brake Oil Temperature Sensor.................................................................................................... 449 Work Equipment Pump Oil Pressure Sensor......................................................................................... 450 Steering Pump Oil Pressure Sensor............................................................................................... 450 Lift Cylinder Head Oil Pressure Sensor.......................................................................................... 450 Lift Cylinder Bottom Oil Pressure Sensor........................................................................................ 450 Transmission Cutoff Oil Pressure Sensor......................................................................................... 451 Coolant Lever Sensor............................................................................................................ 452 Fuel Level Sensor............................................................................................................... 453 Air Cleaner Clogging Sensor..................................................................................................... 454 Accelerator Pedal Sensor........................................................................................................ 455 Water-In-Fuel Sensor............................................................................................................ 456 Boom Kickout Proximity Switch................................................................................................... 457 Bucket Positioner Proximity Switch.............................................................................................. 457 Lift Arm Potentiometer.......................................................................................................... 458 20 STANDARD VALUE TABLES................................................................................................................ 459 STANDARD VALUE TABLES............................................................................................................... 460 Service Value For Engine........................................................................................................ 460 Service Values For Chassis...................................................................................................... 461 POSTURE AND PERFORMANCE MEASUREMENTS................................................................................................ 463 Machine Posture................................................................................................................. 468 30 TESTING AND ADJUSTING................................................................................................................ 471 TOOLS............................................................................................................................... 476 Tools for Testing, Adjusting, and Troubleshooting............................................................................... 476 ENGINE COMPONENTS................................................................................................................... 482 Engine Speed.................................................................................................................... 482 Measure Engine Speed (Low and High Idle).................................................................................... 482 Measure Torque Converter Stall Speed........................................................................................ 482 Measure Hydraulic Stall Speed............................................................................................... 483 Measure Torque Converter Stall and Hydraulic Stall (Full Stall) Speed....................................................... 483 Exhaust Gas Color............................................................................................................... 484 Using Handy Smoke Checker A1................................................................................................ 484 Using Smoke Meter A2........................................................................................................ 484 Valve Clearance................................................................................................................. 486 Engine Compression.............................................................................................................. 488 Blow-by Pressure................................................................................................................ 492 Engine Oil Pressure............................................................................................................. 494 Intake Air (Boost) Pressure..................................................................................................... 495 Determining a Defective Cylinder................................................................................................ 497 Procedures.................................................................................................................. 497 Determining Cylinder Group.................................................................................................. 497 Isolating the Defective Cylinder............................................................................................ 497 FUEL SYSTEM......................................................................................................................... 498 Handling Fuel System Equipment.................................................................................................. 498 Releasing Residual Pressure in Fuel System...................................................................................... 498 Measuring Fuel Pressure......................................................................................................... 499 Measuring Pressure in Fuel Low-pressure Circuit............................................................................. 499 Measuring Pressure in Fuel Return Circuit................................................................................... 500 Measuring Fuel Negative-Pressure Circuit Pressure........................................................................... 501 Fuel Delivery, Return, and Leak Rate............................................................................................ 502 Measuring Supply Pump Delivery.............................................................................................. 502 Measuring Return Rate from Supply Pump...................................................................................... 503 Measuring Leakage from Pressure Limiter..................................................................................... 504 Measuring Return Rate from Injector......................................................................................... 505 Bleeding Air from Fuel Circuit.................................................................................................. 506 Testing Leakage in Fuel System.................................................................................................. 507 Handling Reduced Cylinder Mode Operation........................................................................................ 508 Handling No-Injection Cranking Operation........................................................................................ 508 Handling Controller Voltage Circuit............................................................................................. 508 EXHAUST SYSTEM AND PIPING........................................................................................................... 509 Checking Muffler and Muffler Stack for Looseness and Damage..................................................................... 509 Checking Muffler Function....................................................................................................... 509 Checking Installed Condition of Cylinder Head and Manifolds..................................................................... 509 Checking Engine Piping for Damage and Looseness................................................................................. 509 BELTS............................................................................................................................... 510 Air Conditioner Compressor Belt................................................................................................. 510 Alternator Belt................................................................................................................. 511 DIRECTIONAL LEVER................................................................................................................... 513 Checking Operating Effort....................................................................................................... 513 Checking Stroke................................................................................................................. 513 POWER TRAIN OIL PRESSURES........................................................................................................... 514 Oil Pressure Measuring Points And Gauges........................................................................................ 516 Measuring Transmission Hydraulic Operating Pressures............................................................................ 517 Transmission Main Relief Pressure........................................................................................... 517 Torque Converter Relief Pressure (Inlet).................................................................................... 518 Torque Converter Outlet Pressure............................................................................................ 519 Lockup Clutch Pressure (Lockup Clutch Specification)........................................................................ 520 F (Forward) Clutch Pressure................................................................................................. 521 R (Reverse) Clutch Pressure................................................................................................. 522 1st Clutch Pressure......................................................................................................... 523 2nd Clutch Pressure......................................................................................................... 524 3rd Clutch Pressure......................................................................................................... 525 4th Clutch Pressure......................................................................................................... 526 Lubrication Pressure........................................................................................................ 527 Adjusting Power Train Oil Pressures............................................................................................. 528 Transmission Main Relief Valve.............................................................................................. 528 TRANSMISSION........................................................................................................................ 529 Speed Sensor.................................................................................................................... 529 Flushing Transmission System.................................................................................................... 530 Torque Converter, Transmission, and Hydraulic Circuit....................................................................... 530 Moving the Machine if Transmission Valve Fails.................................................................................. 532 STEERING SYSTEM..................................................................................................................... 536 Steering Stop Valve............................................................................................................. 536 Testing..................................................................................................................... 536 Adjusting................................................................................................................... 536 Steering Wheel.................................................................................................................. 538 Measuring Play in Steering Wheel............................................................................................ 538 Measuring Operating Effort of Steering Wheel................................................................................ 538 Measuring Operating Time of Steering Wheel.................................................................................. 539 Steering Oil Pressure........................................................................................................... 540 Measuring Steering Relief Pressure.......................................................................................... 540 Measuring Steering Pilot Circuit Pressure................................................................................... 541 Adjusting Steering Relief Pressure.......................................................................................... 542 Adjusting Steering Control Circuit Pressure................................................................................. 542 Bleeding Air from Steering Circuit.............................................................................................. 543 Bleeding Air from Steering Pump............................................................................................. 543 Bleeding Air from Steering Cylinder Circuit................................................................................. 543 Steering Column Lock Lever...................................................................................................... 544 HYDRAULIC DRIVE FAN................................................................................................................. 546 Measuring Fan Speed............................................................................................................. 546 Measuring Fan Drive Oil Pressure................................................................................................ 547 Bleeding Air from Hydraulic Drive Fan Circuit................................................................................... 548 Bleeding Air From Fan Pump.................................................................................................. 548 Bleeding Air from Fan Motor Circuit......................................................................................... 549 WHEEL BRAKE SYSTEM.................................................................................................................. 550 Measuring Pressing Angle of Brake Pedal......................................................................................... 550 Measuring Brake Performance..................................................................................................... 551 Accumulator Charge.............................................................................................................. 552 Measuring................................................................................................................... 552 Adjusting................................................................................................................... 553 Measuring Brake Oil Pressure.................................................................................................... 554 Testing Wear of Wheel Brake Disc................................................................................................ 556 Bleeding Air from Brake Circuit................................................................................................. 557 Releasing Residual Pressure in Brake Accumulator Circuit........................................................................ 557 PARKING BRAKE SYSTEM................................................................................................................ 558 Testing Parking Brake Performance............................................................................................... 558 Measuring Parking Brake Oil Pressure............................................................................................ 560 Checking Wear of Parking Brake Disc............................................................................................. 562 Releasing Parking Brake Manually................................................................................................ 563 WORK EQUIPMENT SYSTEM............................................................................................................... 564 Work Equipment Control Levers................................................................................................... 564 Measuring Operating Effort.................................................................................................. 564 Measuring Stroke............................................................................................................ 564 PPC Oil Pressure................................................................................................................ 565 Measuring PPC Valve Basic Pressure.......................................................................................... 565 Measuring PPC Valve Output Pressure......................................................................................... 566 Replacing PPC Relief Valve.................................................................................................. 567 Work Equipment Hydraulic Pressure............................................................................................... 568 Measuring Work Equipment Relief Pressure.................................................................................... 569 Measuring Unload Pressure................................................................................................... 570 Measuring Work Equipment LS Differential Pressure........................................................................... 571 Adjusting Work Equipment Relief Pressure.................................................................................... 572 Adjusting LS Differential Pressure.......................................................................................... 572 Bleeding Air from Work Equipment Circuit........................................................................................ 573 From Work Equipment Pump (Piston Pump)...................................................................................... 573 From Hydraulic Cylinder..................................................................................................... 573 Releasing Residual Pressure in Work Equipment Circuit........................................................................... 574 From Circuit Between Hydraulic Cylinders and Control Valve.................................................................. 574 From ECSS (Travel Damper) Circuit........................................................................................... 574 Work Equipment Positioners...................................................................................................... 575 Bucket Positioner........................................................................................................... 575 Boom Kickout................................................................................................................ 576 Proximity Switch Operation Pilot Lamp........................................................................................... 577 ELECTRICAL SYSTEM TROUBLESHOOTING................................................................................................... 578 Procedure for Testing Diodes.................................................................................................... 578 When Using Digital Type Circuit Tester...................................................................................... 578 When Using Analog Type Circuit Tester....................................................................................... 579 Preparation for Troubleshooting Electric System................................................................................. 580 Machine Monitor............................................................................................................. 580 Transmission Controller..................................................................................................... 581 Work Equipment Controller................................................................................................... 582 KOMTRAX Terminal............................................................................................................ 582 Sensors..................................................................................................................... 583 Boost Pressure and Temperature Sensor (BOOST PRESS & IMT)................................................................... 583 Supply Pump IMV Solenoid (FUEL REGULATOR)................................................................................... 583 Common Rail Pressure Sensor (FUEL RAIL PRESS)............................................................................... 584 Engine Coolant Temperature Sensor (COOLANT TEMP)............................................................................ 584 KOMTRAX TERMINAL SYSTEM............................................................................................................. 585 Terminal Installed at Plant Before Shipment..................................................................................... 585 Terminal Retrofitted Machine After Shipment..................................................................................... 585 Starting Operation.............................................................................................................. 585 Application for the Start of Use............................................................................................ 588 Komtrax Terminal Lamps.......................................................................................................... 590 Display Contents of 7-segment And Dot For CPU............................................................................... 592 MACHINE MONITOR SYSTEM.............................................................................................................. 593 Adjusting Machine Monitor....................................................................................................... 593 Adjusting for Replaced, Reassembled, or Added Sensor/Controller................................................................. 594 Adjustment for User’s Needs..................................................................................................... 595 Special Functions of Machine Monitor (EMMS)..................................................................................... 596 Normal and Special Functions of Machine Monitor............................................................................. 596 Functions and Flow of Service Mode.............................................................................................. 597 Operator Mode................................................................................................................... 600 Service Meter/Clock Display Function (1).................................................................................... 600 Load Meter Function (2) (if equipped)....................................................................................... 600 Odometer Display Function (3)............................................................................................... 600 Maintenance Monitoring Function (4)......................................................................................... 601 Telephone Number Input Function (5)......................................................................................... 601 Language Selection Function (6)............................................................................................. 601 Monitor Brightness Adjustment Function (7).................................................................................. 601 Time Adjustment Function (8)................................................................................................ 602 Travel Speed/Engine Speed Display Selecting Function (9).................................................................... 602 Travel Speed/Engine Speed Display/Non-Display Selecting Function (10)....................................................... 602 Action Code Display Function (11)........................................................................................... 603 Failure Code Display Function (12).......................................................................................... 603 Service Mode.................................................................................................................... 605 Switching to Service Mode and Screen Display (1)............................................................................ 605 Electrical System Fault History Display Function (ELECTRIC FAULT) (2)....................................................... 607 Mechanical System Fault History Display Function (MACHINE FAULT) (3)........................................................ 609 Real-Time Monitoring Function (REAL-TIME MONITOR) (4)....................................................................... 610 Real-Time Monitoring Code Tables............................................................................................ 613 Engine Reduced-Cylinder Function (CYLINDER CUT-OUT) (5)..................................................................... 640 No-Injection Cranking Function (6).......................................................................................... 641 Adjustment Function (TUNING) (7)............................................................................................ 642 Maintenance Monitoring Function (8)......................................................................................... 659 Operating Information Display Function (OPERATION INFO) (9)................................................................. 665 Optional Device Selecting Function (10)..................................................................................... 668 Machine Serial Number Input Function (11)................................................................................... 672 Model Select Function (12).................................................................................................. 672 Initialize Function (13).................................................................................................... 673 PM-CLINIC INSPECTION TABLE.......................................................................................................... 674 40 TROUBLESHOOTING...................................................................................................................... 679 POINTS TO REMEMBER WHEN TROUBLESHOOTING............................................................................................. 694 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................................... 696 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE........................................................................................... 697 Precautions when Handling Electrical Equipment.................................................................................. 697 Handling Electronic Control Unit................................................................................................ 702 Points to Remember when Troubleshooting Electrical Circuits..................................................................... 703 ELECTRIC WIRE CODE.................................................................................................................. 704 Classification by Thickness..................................................................................................... 704 Classification by Color and Code................................................................................................ 704 How to Read Electric Wire Code.................................................................................................. 705 Type, Symbol, and Material.................................................................................................. 705 Dimensions.................................................................................................................. 706 HANDLING HYDRAULIC EQUIPMENT........................................................................................................ 707 CHECKS BEFORE TROUBLESHOOTING....................................................................................................... 709 Categories and Method of Using Troubleshooting Charts........................................................................... 710 Troubleshooting Individual Electrical Circuits.................................................................................. 711 Chart Use................................................................................................................... 713 Chart Tips.................................................................................................................. 713 Troubleshooting Individual Hydraulic Circuits................................................................................... 714 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.......................................................................................... 716 X-Type Connectors............................................................................................................... 716 SWP-Type Connectors............................................................................................................. 718 M-Type Connectors............................................................................................................... 720 S-Type Connectors............................................................................................................... 722 MIC-Type Connectors............................................................................................................. 724 AMP040-Type Connectors.......................................................................................................... 726 AMP070-Type Connectors.......................................................................................................... 728 AMP Connector................................................................................................................... 730 L-Type Connector................................................................................................................ 730 PA-Type Connector............................................................................................................... 731 Bendix (MS) Connector........................................................................................................... 731 KES1 (Automobile) Connectors.................................................................................................... 732 F-Type Connector................................................................................................................ 733 Connectors for Relay (Socket-Type).............................................................................................. 734 HD30 Series Connectors.......................................................................................................... 735 DT Series Connectors............................................................................................................ 741 DTM Series Connectors........................................................................................................... 743 DTHD Series Connectors.......................................................................................................... 743 DTP Series Connectors........................................................................................................... 744 DRC26 Series Connectors......................................................................................................... 745 DRC12, 16 Series Connectors..................................................................................................... 747 AMP Connectors for Pump Controller (CH700)...................................................................................... 748 BOSCH Connectors for Engine..................................................................................................... 749 SUMITOMO Connectors for Engine.................................................................................................. 750 CANNON Connector for Engine..................................................................................................... 751 AMP Connectors for Engine....................................................................................................... 752 FRAMATOME Connectors for Engine................................................................................................. 753 PACKARD Connectors for Engine................................................................................................... 755 DT Series Connectors for Engine................................................................................................. 756 T-BRANCH BOX and T-BRANCH ADAPTER TABLE............................................................................................. 757 MODE CHART.......................................................................................................................... 762 INFORMATION CONTAINED IN TESTING PROCEDURES......................................................................................... 765 TROUBLESHOOTING BY FAILURE CODE..................................................................................................... 767 Failure Code Table.............................................................................................................. 767 FUSE BOX AND SLOW-BLOW FUSES........................................................................................................ 778 Connection Table................................................................................................................ 778 Fuse Box 1.................................................................................................................. 778 Fuse Box 2.................................................................................................................. 779 Slow-Blow Fuses............................................................................................................. 779 FAILURE CODES....................................................................................................................... 781 1500L0.......................................................................................................................... 781 TORQFLOW Transmission: Double Meshing....................................................................................... 781 15SAL1.......................................................................................................................... 782 ECMV F Clutch: When Command Current is OFF, Fill Signal is ON............................................................... 782 15SALH.......................................................................................................................... 784 ECMV F Clutch: When Command Current is ON, Fill Signal is OFF............................................................... 784 15SBL1.......................................................................................................................... 786 ECMV R Clutch: When Command Current is OFF, Fill Signal is ON............................................................... 786 15SBLH.......................................................................................................................... 788 ECMV R Clutch: When Command Current is ON, Fill Signal is OFF............................................................... 788 15SEL1.......................................................................................................................... 790 ECMV 1st Clutch: When Command Current is OFF, Fill Signal is ON............................................................. 790 15SELH.......................................................................................................................... 792 ECMV 1st Clutch: When Command Current is ON, Fill Signal is OFF............................................................. 792 15SFL1.......................................................................................................................... 794 ECMV 2nd Clutch: When Command Current is OFF, FIll Signal is ON............................................................. 794 15SFLH.......................................................................................................................... 796 ECMV 2nd Clutch: When Command Current is ON, Fill Signal is OFF............................................................. 796 15SGL1.......................................................................................................................... 798 ECMV 3rd Clutch: When Command Current is OFF, Fill Signal is ON............................................................. 798 15GLH........................................................................................................................... 800 ECMV 3rd Clutch: When Command Current is ON, Fill Signal is OFF............................................................. 800 15SHL1.......................................................................................................................... 802 ECMV 4th Clutch: When Command Current is OFF, Fill Signal is ON............................................................. 802 15SHLH.......................................................................................................................... 804 ECMV 4th Clutch: When Command Current is ON, Fill Signal is OFF............................................................. 804 2F00MA.......................................................................................................................... 806 Parking Brake: Malfunction.................................................................................................. 806 2G43ZG.......................................................................................................................... 808 Rear Accumulator: Low Oil Pressure.......................................................................................... 808 44K0L4.......................................................................................................................... 810 Bucket Positioner: ON/OFF Signals Disagree.................................................................................. 810 AA1ANX.......................................................................................................................... 814 Air Cleaner: Clogging....................................................................................................... 814 AB00L6.......................................................................................................................... 816 Alternator: Signal Disagrees with Operating State of Engine................................................................. 816 AB00MA.......................................................................................................................... 818 Alternator: Malfunction..................................................................................................... 818 B@BAZG.......................................................................................................................... 820 Engine: Rotation Derating by Low Engine Oil Pressure........................................................................ 820 B@BAZK.......................................................................................................................... 821 Engine Oil: Low Level....................................................................................................... 821 B@BCNS.......................................................................................................................... 822 Engine Coolant: Overheating................................................................................................. 822 B@BCZK.......................................................................................................................... 824 Engine Coolant: Low Level................................................................................................... 824 B@BEBF.......................................................................................................................... 826 Water in Fuel Error......................................................................................................... 826 B@C7NS.......................................................................................................................... 828 Brake Oil: Overheating...................................................................................................... 828 b@CENS.......................................................................................................................... 830 Torque Converter Oil: Overheating........................................................................................... 830 B@CENS.......................................................................................................................... 832 Torque Converter Oil: Overheating........................................................................................... 832 B@HANS.......................................................................................................................... 834 Hydraulic Oil: Overheating.................................................................................................. 834 CA111........................................................................................................................... 836 Abnormality in Engine Controller............................................................................................ 836 CA115........................................................................................................................... 837 Engine Ne or Bkup Speed Sensor Error........................................................................................ 837 CA122........................................................................................................................... 838 Charge Pressure Sensor High Error........................................................................................... 838 CA123........................................................................................................................... 840 Charge Pressure Sensor Low Error............................................................................................ 840 CA131........................................................................................................................... 842 Throttle Sensor High Error.................................................................................................. 842 CA132........................................................................................................................... 844 Throttle Sensor Low Error................................................................................................... 844 CA144........................................................................................................................... 846 Coolant Temperature Sensor High Error....................................................................................... 846 CA145........................................................................................................................... 848 Coolant Temperature Sensor Low Error........................................................................................ 848 CA153........................................................................................................................... 850 Charge Temperature Sensor High Error........................................................................................ 850 CA154........................................................................................................................... 852 Charge Temperature Sensor Low Error......................................................................................... 852 CA155........................................................................................................................... 854 Derating of Speed by Abnormally High Charge Temperature..................................................................... 854 CA187........................................................................................................................... 856 Sensor Power Supply 2 Low Error............................................................................................. 856 CA221........................................................................................................................... 858 Atmospheric Pressure Sensor High Error...................................................................................... 858 CA222........................................................................................................................... 860 Atmospheric Pressure Sensor Low Error....................................................................................... 860 CA227........................................................................................................................... 862 Sensor Power Supply 2 High Error............................................................................................ 862 CA234........................................................................................................................... 864 Engine Overspeed............................................................................................................ 864 CA238........................................................................................................................... 865 Ne Speed Sensor Power Supply Error.......................................................................................... 865 CA271........................................................................................................................... 866 IMV/PCV1 Short Circuit...................................................................................................... 866 CA272........................................................................................................................... 868 IMV/PCV1 Disconnection...................................................................................................... 868 CA322........................................................................................................................... 870 Injector #1 Open/Short Error................................................................................................ 870 CA323........................................................................................................................... 872 Injector #5 Open/Short Error................................................................................................ 872 CA324........................................................................................................................... 874 Injector #3 Open/Short Error................................................................................................ 874 CA325........................................................................................................................... 876 Injector #6 Open/Short Error................................................................................................ 876 CA331........................................................................................................................... 878 Injector #2 Open/Short Error................................................................................................ 878 CA332........................................................................................................................... 880 Injector #4 Open/Short Error................................................................................................ 880 CA342........................................................................................................................... 882 Calibration Code Inconsistency.............................................................................................. 882 CA351........................................................................................................................... 884 Injectors Drive Circuit Error............................................................................................... 884 CA352........................................................................................................................... 886 Sensor Power Supply 1 Low Error............................................................................................. 886 CA386........................................................................................................................... 888 Sensor Power Supply 1 High Error............................................................................................ 888 CA428........................................................................................................................... 890 Abnormally High Level in Water Sensor....................................................................................... 890 CA429........................................................................................................................... 892 Abnormally Low Level in Water Sensor........................................................................................ 892 CA431........................................................................................................................... 894 Idle Validation Switch Error................................................................................................ 894 CA432........................................................................................................................... 898 Idle Validation Action Error................................................................................................ 898 CA435........................................................................................................................... 902 Engine Oil Pressure Switch Error............................................................................................ 902 CA441........................................................................................................................... 904 Battery Voltage Low Error................................................................................................... 904 CA442........................................................................................................................... 908 Battery Voltage High Error.................................................................................................. 908 CA449........................................................................................................................... 910 Common Rail Pressure High Error 2........................................................................................... 910 CA451........................................................................................................................... 914 Common Rail Pressure Sensor High Error...................................................................................... 914 CA452........................................................................................................................... 916 Common Rail Pressure Sensor Low Error....................................................................................... 916 CA488........................................................................................................................... 918 Derating of Torque by Abnormally High Charge Temperature.................................................................... 918 CA553........................................................................................................................... 919 Common Rail Pressure High Error 1........................................................................................... 919 CA559........................................................................................................................... 920 Supply Pump Pressure Very Low Error 1....................................................................................... 920 CA689........................................................................................................................... 922 Engine Ne Speed Sensor Error................................................................................................ 922 CA731........................................................................................................................... 924 Engine Bkup Speed Sensor Phase Error........................................................................................ 924 CA757........................................................................................................................... 925 All Continuous Data Lost Error.............................................................................................. 925 CA778........................................................................................................................... 928 Engine Bkup Speed Sensor Error.............................................................................................. 928 CA1633.......................................................................................................................... 930 KOMNET Datalink Timeout Error............................................................................................... 930 CA2185.......................................................................................................................... 932 Throttle Sensor Power Supply Voltage High Error............................................................................. 932 CA2186.......................................................................................................................... 934 Throttle Sensor Power Supply Voltage Low Error.............................................................................. 934 CA2249.......................................................................................................................... 936 Supply Pump Pressure Very Low Error 2....................................................................................... 936 CA2311.......................................................................................................................... 938 Abnormality in IMV Solenoid................................................................................................. 938 CA2555.......................................................................................................................... 940 Intake Heater Relay Disconnection Error..................................................................................... 940 CA2556.......................................................................................................................... 942 Intake Heater Relay Short Circuit Error..................................................................................... 942 D150KA.......................................................................................................................... 944 Emergency Steering Relay: Disconnection..................................................................................... 944 D150KB.......................................................................................................................... 946 Emergency Steering Relay: Short Circuit..................................................................................... 946 D150KY.......................................................................................................................... 948 Emergency Steering Relay: Short Circuit with Power Supply Line.............................................................. 948 D160KA.......................................................................................................................... 950 Backup Lamp Relay: Disconnection............................................................................................ 950 D160KB.......................................................................................................................... 952 Backup Lamp Relay: Short Circuit............................................................................................ 952 D191KA.......................................................................................................................... 954 Joystick Steering Neutral Safety Relay: Disconnection....................................................................... 954 D191KB.......................................................................................................................... 956 Joystick Steering Neutral Safety Relay: Short Circuit....................................................................... 956 D191KY.......................................................................................................................... 958 Joystick Steering Neutral Safety Relay: Short Circuit with Power Supply Line................................................ 958 D192KA.......................................................................................................................... 960 ECSS Solenoid: Disconnection................................................................................................ 960 D192KB.......................................................................................................................... 962 ECSS Solenoid: Short Circuit................................................................................................ 962 D192KY.......................................................................................................................... 964 ECSS Solenoid Relay: Short Circuit with Power Supply Line................................................................... 964 D193KA.......................................................................................................................... 966 Joystick Steering Solenoid Cut Relay: Disconnection......................................................................... 966 D193KB.......................................................................................................................... 968 Joystick Steering Solenoid Cut Relay: Short Circuit......................................................................... 968 D193KY.......................................................................................................................... 970 Joystick Steering Solenoid Cut Relay: Short Circuit with Power Supply Line.................................................. 970 D5ZHKA.......................................................................................................................... 972 Terminal C Signal: Disconnection............................................................................................ 972 D5ZHKB.......................................................................................................................... 976 Terminal C Signal: Short Circuit............................................................................................ 976 D5ZHKZ.......................................................................................................................... 980 Terminal C Signal: Disconnection or Short Circuit........................................................................... 980 D5ZHL6.......................................................................................................................... 984 Terminal C Signal: Signal Does Not Match Engine Running or Stopped State.................................................... 984 DA80L4.......................................................................................................................... 988 Auto-Grease Controller: ON/OFF Signals Disagree............................................................................. 988 DAF3KK.......................................................................................................................... 990 Machine Monitor: Low Source Voltage (input)................................................................................. 990 DAF5KP.......................................................................................................................... 992 Machine Monitor: Low Output Voltage......................................................................................... 992 DAFRKR.......................................................................................................................... 996 Machine Monitor: CAN Defective Communication................................................................................ 996 DAQ0KK..........................................................................................................................1000 Transmission Controller: Low Source Voltage.................................................................................1000 DAQ0KT..........................................................................................................................1002 Transmission Controller: Abnormality in Controller..........................................................................1002 DAQ2KK..........................................................................................................................1004 Transmission Controller Load Power Supply Line: Low Source Voltage (input)..................................................1004 DAQ9KQ..........................................................................................................................1006 Transmission Controller: Disagreement of Model Selection Signals............................................................1006 DAQRKR..........................................................................................................................1008 CAN Communication with Transmission Controller: Defective Communication.....................................................1008 DAQRMA..........................................................................................................................1011 Transmission Controller Option Setting: Malfunction.........................................................................1011 DB2RKR..........................................................................................................................1012 CAN Communication with Engine Controller: Defective Communication...........................................................1012 DB90KK..........................................................................................................................1016 Work Equipment Controller: Low Source Voltage (input).......................................................................1016 DB90KT..........................................................................................................................1018 Work Equipment Controller: Abnormality in Controller........................................................................1018 DB92KK..........................................................................................................................1020 Work Equipment Controller Load Power Supply Line: Low Source Voltage (input)................................................1020 DD95KX..........................................................................................................................1022 Work Equipment Controller Power Supply Output: Out-of-Input Signal Range....................................................1022 DB99KQ..........................................................................................................................1025 Work Equipment Controller: Disagreement in Model Selection Signals..........................................................1025 DB9RKR..........................................................................................................................1026 CAB Communication with Work Equipment Controller: Defective Communication...................................................1026 DB9RMA..........................................................................................................................1029 Work Equipment Controller Option Setting: Malfunction.......................................................................1029 DB9RMC..........................................................................................................................1030 CAN Communication: Defective Operation......................................................................................1030 DD15LD..........................................................................................................................1034 Switch (Panel Switch 1 n): Switch is Pressed for Long Time..................................................................1034 DD16LD..........................................................................................................................1036 Switch (Panel Switch 2 ‡): Switch is Pressed for Long Time..................................................................1036 DD17LD..........................................................................................................................1038 Switch (Panel Switch 3 <): Switch is Pressed for Long Time..................................................................1038 DD18LD..........................................................................................................................1040 Switch (Panel Switch 4 >): Switch is Pressed for Long Time..................................................................1040 DD1ALD..........................................................................................................................1042 Remote Positioner Raise/Lower Set Switch (raise): Switch is Pressed for Long Time...........................................1042 DD1BLD..........................................................................................................................1044 Remote Positioner Raise/Lower Set Switch (lower): Switch is Pressed for Long Time...........................................1044 DD1CLD..........................................................................................................................1046 Load Meter Subtotal Switch: Switch is Pressed for Long Time.................................................................1046 DD1FLD..........................................................................................................................1048 Load Meter Mode Selector Switch (A/B): Switch is Pressed for Long Time......................................................1048 DD1GLD..........................................................................................................................1050 Load Meter Mode Selector Switch (+/-): Switch is Pressed for Long Time......................................................1050 DD1HLD..........................................................................................................................1052 Load Meter Display Selector Switch: Switch is Pressed for Long Time.........................................................1052 DD1NLD..........................................................................................................................1054 Fan Reverse Switch: Switch is Pressed for Long Time.........................................................................1054 DD1NL4..........................................................................................................................1056 Fan Automatic Reverse Switch: Switch is Pressed for Long Time...............................................................1056 DDB6L4..........................................................................................................................1058 Parking Brake Switch (Neutralizer): ON/OFF Signals Disagree.................................................................1058 DDE5MA..........................................................................................................................1062 Emergency Steering Drive Switch: Malfunction................................................................................1062 DDK3KA..........................................................................................................................1064 Right FNR Switch: Disconnection.............................................................................................1064 DDK4KA..........................................................................................................................1067 Joystick Steering FNR Switch: Disconnection.................................................................................1067 DDK5L4..........................................................................................................................1070 Joystick Steering Shift UP/DOWN Switch: ON/OFF Signals Disagree.............................................................1070 DDK6KA..........................................................................................................................1072 FNR Lever Switch: Disconnection.............................................................................................1072 DDK6KB..........................................................................................................................1075 FNR Lever Switch: Short Circuit.............................................................................................1075 DDS5KA..........................................................................................................................1078 Steering Pressure Switch: Disconnected......................................................................................1078 DDS5KB..........................................................................................................................1080 Steering Pressure Switch: Grounded..........................................................................................1080 DDT0L4..........................................................................................................................1082 Shift Mode Selector Switch: ON/OFF Signals Disagree.........................................................................1082 DDT4LD..........................................................................................................................1084 Transmission Cutoff Set Switch: Switch is Pressed for Long Time.............................................................1084 DDW9LD..........................................................................................................................1086 Kickdown Switch: Switch is Pressed for Long Time............................................................................1086 DDWLLD..........................................................................................................................1088 Hold Switch: Switch is Pressed Down for Long Time...........................................................................1088 DDY0LD..........................................................................................................................1090 Load Meter Cancel Switch: Switch is Pressed for Long Time...................................................................1090 DF10KA..........................................................................................................................1092 Transmission Shift Lever Switch: Disconnected...............................................................................1092 DF10KB..........................................................................................................................1096 Transmission Shift Lever Switch: Short Circuit..............................................................................1096 DGF1KA..........................................................................................................................1100 Transmission Oil Temperature Sensor: Disconnected...........................................................................1100 DGF1KB..........................................................................................................................1102 Transmission Oil Temperature Sensor: Short Circuit..........................................................................1102 DGH2KX..........................................................................................................................1104 Hydraulic Oil Temperature Sensor: Out-of-Input Signal Range.................................................................1104 DGR2KA..........................................................................................................................1106 Rear Brake Oil Temperature Sensor: Disconnected.............................................................................1106 DGR2KX..........................................................................................................................1108 Rear Brake Oil Pressure Sensor: Out-of-Input Signal Range...................................................................1108 DGT1KX..........................................................................................................................1110 Torque Converter Oil Temperature Sensor: Out-of-Input Signal Range..........................................................1110 DH21KA..........................................................................................................................1112 Loader Pump Pressure Sensor: Disconnection..................................................................................1112 DH21KB..........................................................................................................................1114 Loader Pump Pressure Sensor: Power Supply Line Short........................................................................1114 DHPCKX..........................................................................................................................1116 Lift Arm Cylinder Bottom Pressure Sensor: Out-of-Input Signal Range.........................................................1116 DHPDKX..........................................................................................................................1118 Lift Arm Cylinder Head Pressure Sensor: Out-of-Input Signal Range...........................................................1118 DHT1KX..........................................................................................................................1120 Transmission Cutoff Pressure Sensor: Out-of-Input Signal....................................................................1120 DHT8KA..........................................................................................................................1122 Steering Pump Pressure Sensor: Disconnection................................................................................1122 DHT8KB..........................................................................................................................1124 Steering Pump Pressure Sensor: Short Circuit................................................................................1124 DK59KA..........................................................................................................................1126 Lift Arm EPC Lever Potentiometer (Main): Disconnection......................................................................1126 DK59KY..........................................................................................................................1129 Lift Arm EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line...............................................1129 DK59L8..........................................................................................................................1132 Lift Arm EPC Lever Potentiometer (Main): Analog Signals Disagree............................................................1132 DK5AKA..........................................................................................................................1136 Lift Arm EPC Lever Potentiometer (Sub): Disconnection.......................................................................1136 DK5AKY..........................................................................................................................1139 Lift Arm EPC Lever Potentiometer (Sub): Short Circuit with Power Supply LIne................................................1139 DK5BKA..........................................................................................................................1142 Bucket EPC Lever Potentiometer (Main): Disconnection........................................................................1142 DK5BKY..........................................................................................................................1145 Bucket EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line.................................................1145 DK5BL8..........................................................................................................................1148 Bucket EPC Lever Potentiometer (Main): Analog Signals Disagree..............................................................1148 DK5CKA..........................................................................................................................1151 Bucket EPC Lever Potentiometer (Sub): Disconnection.........................................................................1151 DK5CKY..........................................................................................................................1154 Bucket EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line..................................................1154 DK5FKA..........................................................................................................................1157 Joystick Steering EPC Lever Potentiometer (Main): Disconnection.............................................................1157 DK5FKY..........................................................................................................................1160 Joystick Steering EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line......................................1160 DK5GKA..........................................................................................................................1163 Joystick Steering EPC Lever Potentiometer (Sub): Disconnection..............................................................1163 DK5GKY..........................................................................................................................1166 Joystick Steering EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line.......................................1166 DK5FL8..........................................................................................................................1169 Joystick Steering EPC Lever Potentiometer (Main): Analog Signals Disagree...................................................1169 DKA0KA..........................................................................................................................1172 Lift Arm Angle Sensor: Disconnection........................................................................................1172 DKA0KY..........................................................................................................................1176 Lift Arm Angle Sensor: Short Circuit with Power Supply Line.................................................................1176 DKA0L0..........................................................................................................................1178 Lift Arm Angle Sensor: Double Meshing.......................................................................................1178 DLT3KA..........................................................................................................................1180 Transmission Output Shaft Speed Sensor: Disconnection.......................................................................1180 DLT3LC..........................................................................................................................1182 Transmission Output Shaft Speed Sensor: Out-of-Input Signal Range...........................................................1182 DT20KB..........................................................................................................................1184 Transmission Cutoff Indicator Lamp: Short Circuit...........................................................................1184 DUM1KB..........................................................................................................................1186 Remote Positioner Raise Set Indicator Lamp: Short Circuit...................................................................1186 DUM2KB..........................................................................................................................1188 Remote Positioner Lower Set Indicator Lamp: Short Circuit...................................................................1188 DV00KB..........................................................................................................................1190 Alarm Buzzer: Short Circuit.................................................................................................1190 DW4PKA..........................................................................................................................1192 Lift Arm Raise EPC Solenoid: Disconnection..................................................................................1192 DW4PKB..........................................................................................................................1194 Lift Arm Raise EPC Solenoid: Short Circuit..................................................................................1194 DW4PKY..........................................................................................................................1196 Lift Arm Raise EPC Solenoid: Short Circuit with Power Supply Line...........................................................1196 DW4QKA..........................................................................................................................1198 Lift Arm Lower EPC Solenoid: Disconnection..................................................................................1198 DW4QKB..........................................................................................................................1200 Lift Arm Lower EPC Solenoid: Short Circuit..................................................................................1200 DW4QKY..........................................................................................................................1202 Lift Arm Lower EPC Solenoid: Short Circuit with Power Supply Line...........................................................1202 DW4RKA..........................................................................................................................1204 Bucket Tilt EPC Solenoid: Disconnection.....................................................................................1204 DW4RKB..........................................................................................................................1206 Bucket Tilt EPC Solenoid: Short Circuit.....................................................................................1206 DW4RKY..........................................................................................................................1208 Bucket Tilt EPC Solenoid: Short Circuit with Power Supply Line..............................................................1208 DW4SKA..........................................................................................................................1210 Buck Dump EPC Solenoid: Disconnection.......................................................................................1210 DW4SKB..........................................................................................................................1212 Bucket Dump EPC Solenoid: Short Circuit.....................................................................................1212 DW4SKY..........................................................................................................................1214 Bucket Dump EPC Solenoid: Short Circuit with Power Supply Line..............................................................1214 DW7BKA..........................................................................................................................1216 Fan Reverse Solenoid: Disconnection.........................................................................................1216 DW7BKB..........................................................................................................................1218 Fan Reverse Solenoid: Short Circuit.........................................................................................1218 DW7BKY..........................................................................................................................1220 Fan Reverse Solenoid: Short Circuit with Power Supply Line..................................................................1220 DWM1KA..........................................................................................................................1222 Work Equipment Neutral Lock Solenoid: Disconnection.........................................................................1222 DWM1KB..........................................................................................................................1224 Work Equipment Neutral Lock Solenoid: Short Circuit.........................................................................1224 DWM1KY..........................................................................................................................1226 Work Equipment Neutral Lock Solenoid: Short Circuit with Power Supply Line..................................................1226 DWN6KA..........................................................................................................................1228 Lift Arm Raise Magnet Detent Solenoid: Disconnection........................................................................1228 DWN6KB..........................................................................................................................1230 Lift Arm Raise Magnet Detent Solenoid: Short Circuit........................................................................1230 DWN6KY..........................................................................................................................1232 Lift Arm Raise Magnet Detent Solenoid: Short Circuit with Power Supply Line.................................................1232 DWN7KA..........................................................................................................................1234 Lift Arm Float Magnet Detent Solenoid: Disconnection........................................................................1234 DWN7KB..........................................................................................................................1236 Lift Arm Float Magnet Detent Solenoid: Short Circuit........................................................................1236 DWN7KY..........................................................................................................................1238 Lift Arm Float Magnet Detent Solenoid: Short Circuit with Power Supply Line.................................................1238 DWN8KA..........................................................................................................................1240 Bucket Tilt Magnet Detent Solenoid: Disconnection...........................................................................1240 DWN8KB..........................................................................................................................1242 Bucket Tilt Magnet Detent Solenoid: Short Circuit...........................................................................1242 DWN8KY..........................................................................................................................1244 Bucket Tilt Magnet Detent Solenoid: Shorted with the Power Source...........................................................1244 DX16KA..........................................................................................................................1246 Fan Pump EPC Solenoid: Disconnection........................................................................................1246 DX16KB..........................................................................................................................1248 Fan Pump EPC Solenoid: Short Circuit........................................................................................1248 DX16KY..........................................................................................................................1250 Fan Pump EPC Solenoid: Short Circuit with Power Supply Line.................................................................1250 DXH1KA..........................................................................................................................1252 Lockup ECMV Solenoid: Disconnection.........................................................................................1252 DXH1KB..........................................................................................................................1254 Lockup ECMV Solenoid: Short Circuit.........................................................................................1254 DXH1KY..........................................................................................................................1256 Lockup ECMV Solenoid: Short Circuit with Power Supply Line..................................................................1256 DXH4KA..........................................................................................................................1258 1st Clutch ECMV Solenoid: Disconnection.....................................................................................1258 DXH4KB..........................................................................................................................1260 1st Clutch ECMV Solenoid: Short Circuit.....................................................................................1260 DXH4KY..........................................................................................................................1262 1st Clutch ECMV Solenoid: Short Circuit with Power Supply Line..............................................................1262 DXH5KA..........................................................................................................................1264 2nd Clutch ECMV Solenoid: Disconnection.....................................................................................1264 DXH5KB..........................................................................................................................1266 2nd Clutch ECMV Solenoid: Short Circuit.....................................................................................1266 DXH5KY..........................................................................................................................1268 2nd Clutch ECMV Solenoid: Short Circuit with Power Supply Line..............................................................1268 DXH6KA..........................................................................................................................1270 3rd Clutch ECMV Solenoid: Disconnection.....................................................................................1270 DXH6KB..........................................................................................................................1272 3rd Clutch ECMV Solenoid: Short Circuit.....................................................................................1272 DXH6KY..........................................................................................................................1274 3rd Clutch ECMV Solenoid: Short Circuit with Power Supply Line..............................................................1274 DXH7KA..........................................................................................................................1276 R Clutch ECMV Solenoid: Disconnection.......................................................................................1276 DXH7KB..........................................................................................................................1278 R Clutch ECMV Solenoid: Short Circuit.......................................................................................1278 DXH7KY..........................................................................................................................1280 R Clutch ECMV Solenoid: Short Circuit with Power Supply Line................................................................1280 DXH8KA..........................................................................................................................1282 F Clutch ECMV Solenoid: Disconnection.......................................................................................1282 DXH8KB..........................................................................................................................1284 F Clutch ECMV Solenoid: Short Circuit.......................................................................................1284 DXH8KY..........................................................................................................................1286 F Clutch ECMV Solenoid: Short Circuit with Power Supply Line................................................................1286 DXHHKA..........................................................................................................................1288 4th Clutch ECMV Solenoid: Disconnection.....................................................................................1288 DXHHKB..........................................................................................................................1290 4th Clutch ECMV Solenoid: Short Circuit.....................................................................................1290 DXHHKY..........................................................................................................................1292 4th Clutch ECMV Solenoid: Short Circuit with Power Supply Line..............................................................1292 DXHLKA..........................................................................................................................1294 Joystick Steering Right EPC Solenoid: Disconnection.........................................................................1294 DXHLKB..........................................................................................................................1296 Joystick Steering Right EPC Solenoid: Short Circuit.........................................................................1296 DXHLKY..........................................................................................................................1298 Joystick Steering Right EPC Solenoid: Short Circuit with Power Supply Line..................................................1298 DXHMKA..........................................................................................................................1300 Joystick Steering Left EPC Solenoid: Disconnection..........................................................................1300 DXHMKB..........................................................................................................................1302 Joystick Steering Left EPC Solenoid: Short Circuit..........................................................................1302 DXHMKY..........................................................................................................................1304 Joystick Steering Left EPC Solenoid: Short Circuit with Power Supply Line...................................................1304 DY30MA..........................................................................................................................1306 Motor-Driven Emergency Steering Pump Failure (during Operation of machine)..................................................1306 DY30MC..........................................................................................................................1309 Motor-Driven Emergency Steering Pump Failure (Malfunction in Manual Mode)...................................................1309 TROUBLESHOOTING: E-MODE.............................................................................................................1312 Troubleshooting Electrical System...............................................................................................1312 Information in Troubleshooting Table........................................................................................1312 E-1.............................................................................................................................1314 Engine Does Not Start.......................................................................................................1314 E-2.............................................................................................................................1320 Wiper Does Not Operate......................................................................................................1320 E-3.............................................................................................................................1324 Windshield Washer Does Not Operate..........................................................................................1324 E-4.............................................................................................................................1328 Headlamp, Clearance Lamp, Tail Lamp, and License Lamp Do Not Light Up or Go Off.............................................1328 E-5.............................................................................................................................1336 Working Lamp Does Not Light Up or Go Off....................................................................................1336 E-6.............................................................................................................................1342 Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off..................................................................1342 E-7.............................................................................................................................1348 Brake Lamp Does Not Light or It Keeps Lighting Up...........................................................................1348 E-8.............................................................................................................................1351 Backup Lamp Does Not Light or It Keeps Lighting Up..........................................................................1351 E-9.............................................................................................................................1354 Backup Buzzer Does Not Sound or It Keeps Sounding...........................................................................1354 E-10............................................................................................................................1357 Horn Does Not Sound or It Keeps Sounding....................................................................................1357 E-11............................................................................................................................1360 Alarm Buzzer Does Not Sound or It Keeps Sounding............................................................................1360 E-12............................................................................................................................1362 Air Conditioner Does Not Operate or Stop....................................................................................1362 E-13............................................................................................................................1366 KOMTRAX System Does Not Work Properly.......................................................................................1366 Indicator Lamps of KOMTRAX Terminal.....................................................................................1368 E-14............................................................................................................................1370 When Kickdown Switch is Turned On, Kickdown Operation Does Not Start........................................................1370 E-15............................................................................................................................1372 When Hold Switch is Pressed, Holding Operation Does Not Start...............................................................1372 E-16............................................................................................................................1374 Transmission Kept in Neutral or Brake Drags when Directional Lever is Operated While Parking Brake is Applied...............1374 E-17............................................................................................................................1376 Transmission Cutoff Mode Cannot Be Set or Reset.............................................................................1376 E-18............................................................................................................................1378 Transmission Cutoff Set Cannot be Reset.....................................................................................1378 E-19............................................................................................................................1380 FNR Switch Mode Cannot Be Set or Reset......................................................................................1380 E-20............................................................................................................................1382 Fan Reverse Function Cannot Be Used or Reset................................................................................1382 E-21............................................................................................................................1384 Discharge from Loader Pump Does Not Rise from Minimum Level.................................................................1384 E-22............................................................................................................................1386 ECSS Function Cannot Be Used or Reset.......................................................................................1386 E-23............................................................................................................................1388 When Parking Brake is Turned On, Parking Brake Indicator Lamp Does Not Light Up.............................................1388 E-24............................................................................................................................1392 When Emergency Brake Operates, Brake Oil Pressure Caution Lamp Does Not Operate.............................................1392 E-25............................................................................................................................1394 Air Cleaner Clogging Indicator Lamp Does Not Light Up.......................................................................1394 E-26............................................................................................................................1396 Radiator Coolant Level Caution Lamp Does Not Light Up.......................................................................1396 E-27............................................................................................................................1398 Hydraulic Oil Temperature Gauge Does Not Rise and Hydraulic Oil Temperature Caution Lamp Does Not Light Up..................1398 E-28............................................................................................................................1400 Torque Converter Oil Temperature Gauge Does Not Rise and Torque Converter Oil Temperature Caution Lamp Does Not Light Up....1400 E-29............................................................................................................................1402 Steering Oil Pressure Caution Lamp Does Not Light Up........................................................................1402 E-30............................................................................................................................1404 Abnormality in Switch (n) (Panel Switch 1) Input............................................................................1404 E-31............................................................................................................................1406 Abnormality in Switch (‡) (Panel Switch 2) Input............................................................................1406 E-32............................................................................................................................1408 Abnormality in Switch (<) (Panel Switch 3) Input............................................................................1408 E-33............................................................................................................................1410 Abnormality in Switch (>) (Panel Switch 4) Input............................................................................1410 TROUBLESHOOTING: H-MODE.............................................................................................................1412 Troubleshooting Hydraulic and Mechanical Systems................................................................................1412 Using Troubleshooting Chart.................................................................................................1412 Failure Codes and Causes Table..................................................................................................1414 H-1.............................................................................................................................1418 Machine Does Not Start......................................................................................................1418 H-2.............................................................................................................................1420 Torque Converter Lockup is Not Switched OFF (Engine Stalls).................................................................1420 H-3.............................................................................................................................1421 Torque Converter Lockup is Not Switched ON..................................................................................1421 H-4.............................................................................................................................1422 Travel Speed is Slow, Thrusting Force is Weak, Uphill Traveling Power is Weak, Gear is Not Shifted..........................1422 H-5.............................................................................................................................1426 Large Shocks When Starting and Shifting Gears...............................................................................1426 H-6.............................................................................................................................1430 Large Time Lag When Starting and Shifting Gear..............................................................................1430 H-7.............................................................................................................................1434 Torque Converter Oil Temperature is High....................................................................................1434 H-8.............................................................................................................................1435 Steering Does Not Turn......................................................................................................1435 H-9.............................................................................................................................1436 Steering Does Not Turn (Joystick Steering, if equipped).....................................................................1436 H-10............................................................................................................................1437 Steering Response is Poor...................................................................................................1437 H-11............................................................................................................................1438 Steering, Turning Response is Poor (Joystick Steering, if Equipped).........................................................1438 H-12............................................................................................................................1439 Steering is Heavy...........................................................................................................1439 H-13............................................................................................................................1440 When Machine Turns, It Shakes or Jerks......................................................................................1440 H-14............................................................................................................................1441 When Machine Turns, It Shakes or Jerks (Joystick Steering, if Equipped).....................................................1441 H-15............................................................................................................................1442 Wheel Brake Does Not Work or Does Not Work Well.............................................................................1442 H-16............................................................................................................................1443 Wheel Brake is Not Released or It Drags.....................................................................................1443 H-17............................................................................................................................1444 Parking Brake Does Not Work or Does Not Work Well...........................................................................1444 H-18............................................................................................................................1445 Parking Brake is Not Released or It Drags...................................................................................1445 H-19............................................................................................................................1446 Lift Arm Does Not Rise......................................................................................................1446 H-20............................................................................................................................1447 Lift Arm Speed is Low or Rising Force is Insufficient.......................................................................1447 H-21............................................................................................................................1448 When Rising, Lift Arm Starts to Move Slowly at a Specific Height............................................................1448 H-22............................................................................................................................1448 Lift Arm Cylinder Cannot Hold Down Bucket (Bucket Floats)...................................................................1448 H-23............................................................................................................................1448 Hydraulic Drifts of the Lift Arm Are Large..................................................................................1448 H-24............................................................................................................................1449 Lift Arm Wobbles During Operation...........................................................................................1449 H-25............................................................................................................................1450 Bucket Does Not Tilt Back...................................................................................................1450 H-26............................................................................................................................1451 Bucket Speed is Low or Tilting-Back Force Is Insufficient...................................................................1451 H-27............................................................................................................................1452 Bucket Starts to Operate Slowly in the Midst of Tilting Back................................................................1452 H-28............................................................................................................................1452 Bucket Cylinder Cannot Hold Down the Bucket.................................................................................1452 H-29............................................................................................................................1452 Hydraulic Drifts of the Bucket Are Large....................................................................................1452 H-30............................................................................................................................1453 Bucket Wobbles During Travel with Load......................................................................................1453 H-31............................................................................................................................1454 Lift Arm and Bucket Control Levers Do Not Move Smoothly and Are Heavy.......................................................1454 H-32............................................................................................................................1455 During Operation of Machine, Engine Speed Drops Remarkably or Engine Stalls.................................................1455 H-33............................................................................................................................1455 Large Shocks When Work Equipment Starts and Stops...........................................................................1455 H-34............................................................................................................................1455 When Work Equipment Circuit is Relieved Singly, Other Work Equipment Moves..................................................1455 H-35............................................................................................................................1456 ECSS Does Not Operate; Pitching and Bouncing Occur..........................................................................1456 50 DISASSEMBLY AND ASSEMBLY.............................................................................................................1457 HOW TO READ THIS MANUAL.............................................................................................................1461 Removal and Installation of Assemblies..........................................................................................1461 Disassembly and Assembly of Assemblies..........................................................................................1463 COATING MATERIALS LIST..............................................................................................................1465 SPECIAL TOOLS LIST..................................................................................................................1468 SKETCHES OF SPECIAL TOOLS...........................................................................................................1471 CONNECTOR REPAIR PROCEDURES.........................................................................................................1477 Stripping Insulation............................................................................................................1477 Wire Inspection.................................................................................................................1477 Contact Terminal Removal (HD30 Type)............................................................................................1478 Crimping Contact Terminal (HD30 Type)...........................................................................................1479 Insertion Of Contact Terminal (HD30 Type).......................................................................................1480 Contact Terminal Removal (DT Type)..............................................................................................1481 Crimping Contact Terminal (DT Type).............................................................................................1482 Insertion Of Contact Terminal (DT Type).........................................................................................1483 ENGINE AND COOLING SYSTEM...........................................................................................................1484 Alternator......................................................................................................................1484 Crankshaft......................................................................................................................1484 Camshaft........................................................................................................................1484 Engine Front Seal...............................................................................................................1484 Engine Oil Cooler...............................................................................................................1484 Engine Rear Seal................................................................................................................1484 Starting Motor..................................................................................................................1484 Thermostat......................................................................................................................1484 Turbocharger....................................................................................................................1484 Water Pump......................................................................................................................1484 Cylinder Head...................................................................................................................1485 Removal.....................................................................................................................1485 Installation................................................................................................................1491 Engine Hood.....................................................................................................................1498 Removal.....................................................................................................................1498 Installation................................................................................................................1500 Radiator........................................................................................................................1501 Removal.....................................................................................................................1501 Installation................................................................................................................1502 Air Aftercooler.................................................................................................................1503 Removal.....................................................................................................................1503 Installation................................................................................................................1504 Hydraulic Oil Cooler............................................................................................................1505 Removal.....................................................................................................................1505 Installation................................................................................................................1506 Engine..........................................................................................................................1507 Removal.....................................................................................................................1507 Installation................................................................................................................1512 Cooling Fan and Fan Motor.......................................................................................................1514 Removal.....................................................................................................................1514 Installation................................................................................................................1517 FUEL SUPPLY SYSTEM..................................................................................................................1518 Fuel Supply Pump................................................................................................................1518 Removal.....................................................................................................................1518 Installation................................................................................................................1519 Fuel Injector...................................................................................................................1520 Removal.....................................................................................................................1520 Installation................................................................................................................1523 Fuel Tank.......................................................................................................................1528 Removal.....................................................................................................................1528 Installation................................................................................................................1530 POWER TRAIN.........................................................................................................................1531 Torque Converter and Transmission Assembly......................................................................................1531 Removal.....................................................................................................................1531 Installation................................................................................................................1538 Torque Converter (Standard Specification).......................................................................................1539 Disassembly.................................................................................................................1539 Assembly....................................................................................................................1542 Torque Converter (Lockup Specification).........................................................................................1545 Disassembly.................................................................................................................1545 Assembly....................................................................................................................1548 Transmission....................................................................................................................1553 Disassembly.................................................................................................................1553 Assembly....................................................................................................................1563 Clutch Pack.....................................................................................................................1574 Forward and Reverse Clutch Pack: Disassembly................................................................................1574 1st and 4th Clutch Pack: Disassembly........................................................................................1578 2nd and 3rd Gear Clutch Pack: Disassembly...................................................................................1581 Forward and Reverse Clutch Pack: Assembly...................................................................................1587 1st and 4th Clutch Pack: Assembly...........................................................................................1591 2nd and 3rd Clutch Pack: Assembly...........................................................................................1595 Parking Brake...................................................................................................................1600 Disassembly.................................................................................................................1600 Assembly....................................................................................................................1605 Front Axle......................................................................................................................1612 Removal.....................................................................................................................1612 Installation................................................................................................................1613 Rear Axle.......................................................................................................................1614 Removal.....................................................................................................................1614 Installation................................................................................................................1617 Axle Housing....................................................................................................................1619 Disassembly.................................................................................................................1619 Assembly....................................................................................................................1624 Differential Assembly...........................................................................................................1631 Disassembly.................................................................................................................1631 Assembly....................................................................................................................1640 STEERING SYSTEM.....................................................................................................................1656 Steering Valve Assembly.........................................................................................................1656 Removal.....................................................................................................................1656 Installation................................................................................................................1658 BRAKING SYSTEM......................................................................................................................1659 Parking Brake Discs and Plates..................................................................................................1659 Removal.....................................................................................................................1659 Installation................................................................................................................1661 UNDERCARRAGE AND FRAME..............................................................................................................1662 Center Hinge Pin................................................................................................................1662 Removal.....................................................................................................................1662 Installation................................................................................................................1667 Counterweight...................................................................................................................1672 Removal.....................................................................................................................1672 Installation................................................................................................................1674 HYDRAULIC SYSTEM....................................................................................................................1675 Work Equipment Control Valve....................................................................................................1675 Removal.....................................................................................................................1675 Installation................................................................................................................1677 Power Train Pump and Work Equipment Pump Assembly...............................................................................1678 Removal.....................................................................................................................1678 Installation................................................................................................................1678 Steering Pump And Cooling Fan Pump Assembly.....................................................................................1679 Removal.....................................................................................................................1679 Installation................................................................................................................1680 Hydraulic Tank..................................................................................................................1681 Removal.....................................................................................................................1681 Installation................................................................................................................1684 WORK EQUIPMENT......................................................................................................................1685 Work Equipment Assembly.........................................................................................................1685 Removal.....................................................................................................................1685 Installation................................................................................................................1688 Hydraulic Cylinder..............................................................................................................1690 Disassembly.................................................................................................................1690 Assembly....................................................................................................................1694 CAB AND ATTACHMENTS.................................................................................................................1699 Cab and Floor Frame.............................................................................................................1699 Removal.....................................................................................................................1699 Installation................................................................................................................1702 Cab Glass (Stuck Glass).........................................................................................................1703 Removal.....................................................................................................................1703 Installation................................................................................................................1704 Operator Seat Assembly (Standard Specification) (ISRING HAUSEN).................................................................1712 Disassembly.................................................................................................................1712 Assembly....................................................................................................................1719 Operator Seat Assembly (GRAMMER)................................................................................................1724 Upper Seat..................................................................................................................1724 Suspension..................................................................................................................1732 AIR CONDITIONER UNIT ASSEMBLY.......................................................................................................1760 Removal.........................................................................................................................1760 Installation....................................................................................................................1764 ELECTRICAL SYSTEM...................................................................................................................1765 Engine Controller Assembly......................................................................................................1765 Removal.....................................................................................................................1765 Installation................................................................................................................1765 90 DIAGRAMS AND SCHEMATICS..............................................................................................................1767 AUTOMATIC GREASING..................................................................................................................1769 Auto-Grease Circuit Diagram.....................................................................................................1769 HYDRAULIC SYSTEM....................................................................................................................1770 Power Train Hydraulic Circuit Diagram...........................................................................................1770 Without Lockup Clutch.......................................................................................................1770 With Lockup Clutch..........................................................................................................1770 Hydraulic Circuit Diagram.......................................................................................................1771 ELECTRICAL SYSTEM...................................................................................................................1772 Machine Monitor System Circuit Diagram..........................................................................................1772 Transmission Controller System Circuit Diagram..................................................................................1773 Work Equipment Controller System Circuit Diagram................................................................................1774 Work Equipment Controller System Electrical Circuit Diagram.....................................................................1775 Electrical Circuit Diagram (1/14)...............................................................................................1776 Electrical Circuit Diagram (2/14)...............................................................................................1777 Electrical Circuit Diagram (3/14)...............................................................................................1778 Electrical Circuit Diagram (4/14)...............................................................................................1779 Electrical Circuit Diagram (5/14)...............................................................................................1780 Electrical Circuit Diagram (6/14)...............................................................................................1781 Electrical Circuit Diagram (7/14)...............................................................................................1782 Electrical Circuit Diagram (8/14)...............................................................................................1783 Electrical Circuit Diagram (9/14)...............................................................................................1784 Electrical Circuit Diagram (10/14)..............................................................................................1785 Electrical Circuit Diagram (11/14)..............................................................................................1786 Electrical Circuit Diagram (12/14)..............................................................................................1787 Electrical Circuit Diagram (13/14)..............................................................................................1788 Electrical Circuit Diagram (14/14)..............................................................................................1789 Connector List and Stereogram...................................................................................................1790 Chassis.....................................................................................................................1790 Engine and Transmission.....................................................................................................1791 Operator’s Compartment......................................................................................................1792
Please Note:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
