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KOMATSU WA380-7 WHEEL LOADER SERVICE REPAIR MANUAL – PDF Download
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Description
KOMATSU WA380-7 WHEEL LOADER SERVICE REPAIR MANUAL
KOMATSU WA380-7 WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
SCREENSHOT OF THE MANUAL:
DESCRIPTION:
KOMATSU WA380-7 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 judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
- 01. GENERAL : This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
- 10. STRUCTURE AND FUNCTION : 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. This section gives the judgement standards when inspecting disassembled parts.
- 20. STANDARD VALUE TABLE : This section explains the standard values for new machine and judgement criteria for testing, adjusting and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
- 30. 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.
- 40. TROUBLESHOOTING : Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
- 50. 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.
- 60. MAINTENANCE STANDARD : This section gives the judgement standards when inspecting disassembled parts.
- 80. AIR CONDITIONER : This section explains the structure, function testing adjusting and troubleshooting for the air conditioning system.
- 90. DIAGRAMS AND SCHEMATICS : This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
KOMATSU WA380-7 WHEEL LOADER SERVICE REPAIR MANUAL
CEBM025604 WA380-7 S/N A64001 and UP........................................................................................................................ 1 CONTENTS................................................................................................................................................ 2 00 FOREWORD............................................................................................................................................. 24 SAFETY.............................................................................................................................................. 24 Safety Notice................................................................................................................................... 24 Important Safety Notice..................................................................................................................... 24 General Precautions......................................................................................................................... 24 Preparations For Work....................................................................................................................... 25 Precautions During Work..................................................................................................................... 25 GENERAL............................................................................................................................................. 28 HOW TO READ THE SHOP MANUAL......................................................................................................................... 29 Volumes......................................................................................................................................... 29 Distribution And Updating....................................................................................................................... 29 Filing Method................................................................................................................................... 29 Revised Edition Mark............................................................................................................................ 29 Revisions....................................................................................................................................... 29 Symbols......................................................................................................................................... 29 Unit............................................................................................................................................ 29 HOISTING INSTRUCTIONS............................................................................................................................... 30 Hoisting........................................................................................................................................ 30 Making Signs.................................................................................................................................... 30 Precautions..................................................................................................................................... 30 Precautions for Sling Work.................................................................................................................. 30 Precautions for Using Mobile Crane.......................................................................................................... 31 Precautions for Using Overhead Hoist Crane.................................................................................................. 31 Selecting Wire Ropes............................................................................................................................ 33 HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS................................................................................................ 34 Points to Remember When Handling Electric Equipment............................................................................................. 34 Points to Remember When Handling Hydraulic Equipment............................................................................................ 46 PUSH PULL COUPLER................................................................................................................................... 48 Type 1.......................................................................................................................................... 48 Disconnection............................................................................................................................... 48 Connection.................................................................................................................................. 48 Type 2.......................................................................................................................................... 49 Disconnection............................................................................................................................... 49 Connection.................................................................................................................................. 49 Type 3.......................................................................................................................................... 50 Disconnection............................................................................................................................... 50 Connection.................................................................................................................................. 50 EXPLANATION OF MAINTENANCE STANDARD TERMS........................................................................................................... 51 HANDLING OF FUEL SYSTEM DEVICES..................................................................................................................... 52 HANDLING OF INTAKE SYSTEM PARTS..................................................................................................................... 53 STANDARD TIGHTENING TORQUE.......................................................................................................................... 54 Bolts and Nuts.................................................................................................................................. 54 Tightening Torque of Hose Nuts.................................................................................................................. 55 Tightening Torque of Split Flange Bolts......................................................................................................... 55 Tightening Torque for Flared Nuts............................................................................................................... 55 Tightening Torques for Split Flanged Bolts...................................................................................................... 56 Tightening Torques for O-ring Boss Piping Joints................................................................................................ 56 Table Of Tightening Torques for O-ring Boss Plugs............................................................................................... 56 Tightening Torque for Hoses (Taper Seal Type and Face Seal Type)................................................................................ 57 Tightening Torque for Face Seal Joints.......................................................................................................... 57 For 102, 107, and 114 Engine Series (Bolts and Nuts)............................................................................................ 57 For 102, 107, and 114 Engine Series (Eye Joints)................................................................................................ 58 For 102, 107, and 114 Engine Series (Taper Screws).............................................................................................. 58 ELECTRIC WIRE CODE.................................................................................................................................. 59 Classification By Thickness..................................................................................................................... 59 Classification By Color And Code................................................................................................................ 59 How To Read Electric Wire Code.................................................................................................................. 60 PRECAUTIONS FOR OPERATIONS.......................................................................................................................... 64 Precautions When Carrying Out Removal Work...................................................................................................... 64 Precautions When Carrying Out Installation Work................................................................................................. 65 Precautions When Completing the Operation....................................................................................................... 66 CONVERSION TABLES................................................................................................................................... 67 Method Of Using The Conversion Table............................................................................................................ 67 COATING MATERIALS................................................................................................................................... 73 LIST OF ABBREVIATIONS............................................................................................................................... 75 List of Abbreviations Used in the Shop Manual................................................................................................... 75 List of Abbreviations Used in the Circuit Diagrams.............................................................................................. 79 01 GENERAL.............................................................................................................................................. 81 SPECIFICATIONS...................................................................................................................................... 82 Dimension Drawing............................................................................................................................... 82 Specification Tables............................................................................................................................ 84 WEIGHT TABLE........................................................................................................................................ 90 FUEL, COOLANT, AND LUBRICANTS....................................................................................................................... 92 10 STRUCTURE AND FUNCTION............................................................................................................................... 95 ENGINE AND COOLING SYSTEM........................................................................................................................... 104 Engine Related Parts............................................................................................................................ 104 KVGT............................................................................................................................................ 106 Operation................................................................................................................................... 107 EGR System Piping Drawing....................................................................................................................... 112 Function.................................................................................................................................... 113 EGR System Circuit Diagram...................................................................................................................... 114 EGR Valve....................................................................................................................................... 115 Structure................................................................................................................................... 115 Operation................................................................................................................................... 116 EGR Cooler...................................................................................................................................... 117 Operation................................................................................................................................... 117 KCCV Layout Drawing............................................................................................................................. 118 Operation................................................................................................................................... 119 KCCV Ventilator................................................................................................................................. 120 Function.................................................................................................................................... 120 Operation................................................................................................................................... 121 CDR Valve................................................................................................................................... 121 KDPF............................................................................................................................................ 122 Function.................................................................................................................................... 124 Types of Regeneration....................................................................................................................... 124 Cooling System.................................................................................................................................. 126 Specification............................................................................................................................... 127 Cooling Fan Pump................................................................................................................................ 128 Specification............................................................................................................................... 130 Function.................................................................................................................................... 131 Operation................................................................................................................................... 131 Servo Valve..................................................................................................................................... 132 Function.................................................................................................................................... 133 Operation................................................................................................................................... 133 Cooling Fan Motor System........................................................................................................................ 134 Specifications.............................................................................................................................. 134 Hydraulic Motor................................................................................................................................. 136 Suction Valve................................................................................................................................... 137 Function.................................................................................................................................... 137 Operation................................................................................................................................... 137 Reversible Valve................................................................................................................................ 138 Safety Valve.................................................................................................................................... 139 POWER TRAIN SYSTEM.................................................................................................................................. 140 Power Train System.............................................................................................................................. 140 System Diagram.................................................................................................................................. 142 Drive Shaft System.............................................................................................................................. 144 Function.................................................................................................................................... 144 Power Train Piping System....................................................................................................................... 145 Transmission Control............................................................................................................................ 146 Function.................................................................................................................................... 147 Torque Converter................................................................................................................................ 148 Specification............................................................................................................................... 148 Power Transmitting Route........................................................................................................................ 149 Oil Flow.................................................................................................................................... 150 Transmission.................................................................................................................................... 152 Forward and Reverse Clutches.................................................................................................................... 157 1st and 4th Clutches........................................................................................................................ 158 2nd and 3rd Clutches........................................................................................................................ 159 Structure................................................................................................................................... 159 Operation of Clutch Pack.................................................................................................................... 161 Power Transmitting Route........................................................................................................................ 162 Forward 1st................................................................................................................................. 162 Forward 2nd................................................................................................................................. 164 Forward 3rd................................................................................................................................. 166 Forward 4th................................................................................................................................. 168 Reverse 1st................................................................................................................................. 170 Transmission Control Valve...................................................................................................................... 172 Function.................................................................................................................................... 173 Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV...................................................................................... 174 ECMV For Gear Speed Clutch.................................................................................................................. 175 Lockup Clutch ECMV.............................................................................................................................. 178 ECMV for Lockup Clutch...................................................................................................................... 179 Operation................................................................................................................................... 179 Main and Torque Converter Relief Valve System................................................................................................... 181 Function.................................................................................................................................... 182 Operation................................................................................................................................... 182 DRIVE AXLE SYSTEM................................................................................................................................... 184 Front Axle Assembly............................................................................................................................. 184 Rear Axle Assembly.............................................................................................................................. 185 Front Differential.............................................................................................................................. 186 Rear Differential............................................................................................................................... 187 Operation................................................................................................................................... 188 Limited Slip Differential....................................................................................................................... 189 Operation................................................................................................................................... 189 Final Drive..................................................................................................................................... 192 STEERING SYSTEM..................................................................................................................................... 194 Layout of Steering Devices...................................................................................................................... 194 Steering Column................................................................................................................................. 195 Steering Pump................................................................................................................................... 196 Pump Body................................................................................................................................... 198 Specification............................................................................................................................... 201 Operation................................................................................................................................... 201 Servo Valve................................................................................................................................. 203 LS Valve.................................................................................................................................... 206 PC Valve.................................................................................................................................... 206 Steering Valve.................................................................................................................................. 210 Operation of Flow Amplifier................................................................................................................. 212 Operation of Flow Control Spool............................................................................................................. 213 Operation of Steering Valve................................................................................................................. 215 Steering Relief Valve....................................................................................................................... 218 Overload Relief Valve....................................................................................................................... 219 Relief Valve................................................................................................................................ 220 Orbitrol Valve.................................................................................................................................. 221 Stop Valve...................................................................................................................................... 225 Emergency Steering Motor........................................................................................................................ 226 Function.................................................................................................................................... 226 Specifications.............................................................................................................................. 226 Emergency Steering Pump......................................................................................................................... 227 Specification............................................................................................................................... 227 BRAKE SYSTEM........................................................................................................................................ 228 Layout of brake parts........................................................................................................................... 228 Charge Valve.................................................................................................................................... 229 Brake Valve..................................................................................................................................... 235 Function.................................................................................................................................... 235 Accumulator (for Brakes)........................................................................................................................ 240 Function.................................................................................................................................... 240 Specifications.............................................................................................................................. 240 Brakes.......................................................................................................................................... 241 Front Brake................................................................................................................................. 241 Rear Brake.................................................................................................................................. 242 Operation................................................................................................................................... 243 Parking Brake System............................................................................................................................ 244 Brake Control............................................................................................................................... 244 Parking Brake Unit.......................................................................................................................... 245 Parking Brake Solenoid Valve................................................................................................................ 246 Emergency Parking Brake Release Valve....................................................................................................... 247 UNDERCARRIAGE AND FRAME............................................................................................................................. 248 Axle Mounting and Center Hinge Pin.............................................................................................................. 248 Tires........................................................................................................................................... 249 Radial Ply Tire............................................................................................................................. 249 Bias Tire................................................................................................................................... 250 HYDRAULIC SYSTEM.................................................................................................................................... 252 Hydraulic Component Layout...................................................................................................................... 252 Work Equipment Control Lever System............................................................................................................. 254 3-Lever Type................................................................................................................................ 254 Multi-Function Mono-Lever Type.............................................................................................................. 255 Hydraulic Tank.................................................................................................................................. 256 Specifications.............................................................................................................................. 257 Breather.................................................................................................................................... 257 Double Type Gear Pump........................................................................................................................... 258 Specification............................................................................................................................... 258 Function.................................................................................................................................... 258 Work Equipment Pump............................................................................................................................. 260 Pump Body....................................................................................................................................... 262 Function.................................................................................................................................... 264 Structure................................................................................................................................... 264 Specification............................................................................................................................... 265 Operation................................................................................................................................... 265 Servo Valve..................................................................................................................................... 268 LS Valve.................................................................................................................................... 271 PC Valve.................................................................................................................................... 272 Control Valve................................................................................................................................... 276 Structure................................................................................................................................... 285 CLSS............................................................................................................................................ 286 Outline of CLSS............................................................................................................................. 286 Features........................................................................................................................................ 286 Structure................................................................................................................................... 286 Basic Principle............................................................................................................................. 287 Pressure Compensation Control............................................................................................................... 288 Function and Operation of Each Valve............................................................................................................ 290 Hydraulic Circuit Diagram of Valves......................................................................................................... 290 Unload Valve................................................................................................................................ 291 Work Equipment Valve (Supply of LS Pressure)................................................................................................ 294 LS Bypass Plug.............................................................................................................................. 296 Pressure Compensation Valve................................................................................................................. 298 Boom Regeneration Circuit................................................................................................................... 302 Variable Back Pressure Valve................................................................................................................ 304 ECSS Control Valve.......................................................................................................................... 305 Accumulator Charge Valve.................................................................................................................... 306 Stabilizer Valve............................................................................................................................ 310 Work Equipment Lock Solenoid Valve.......................................................................................................... 315 Accumulator (for PPC Circuit)................................................................................................................... 316 Function.................................................................................................................................... 316 Specifications.............................................................................................................................. 316 Accumulator (for ECSS).......................................................................................................................... 317 WORK EQUIPMENT...................................................................................................................................... 318 Work Equipment Linkage.......................................................................................................................... 318 Bucket.......................................................................................................................................... 319 Bucket Positioner and Boom Positioner........................................................................................................... 320 CAB AND ITS ATTACHMENTS............................................................................................................................. 321 ROPS Cab........................................................................................................................................ 321 ELECTRICAL SYSTEM................................................................................................................................... 322 Engine Control System........................................................................................................................... 322 Function.................................................................................................................................... 323 Operation................................................................................................................................... 323 Preheating System............................................................................................................................... 324 Automatic Preheating System................................................................................................................. 324 Manual Preheating System.................................................................................................................... 325 Engine Power Mode Selector Circuit.............................................................................................................. 326 Function.................................................................................................................................... 326 Operation................................................................................................................................... 326 Engine Output Limit Function.................................................................................................................... 327 Automatic Warm-up Function...................................................................................................................... 327 Parking Brake Control System.................................................................................................................... 328 Operation................................................................................................................................... 328 System Operating Lamp Function.................................................................................................................. 332 Function.................................................................................................................................... 332 Battery Disconnect Switch Function.............................................................................................................. 334 Function.................................................................................................................................... 334 Transmission Controller System.................................................................................................................. 336 Transmission Controller System Diagram...................................................................................................... 336 Transmission Gear Shift Control Function.................................................................................................... 338 Transmission Protection Function............................................................................................................ 356 Engine Control Function..................................................................................................................... 358 ECSS Function............................................................................................................................... 368 Directional Switch Control Function......................................................................................................... 369 Auto Idle Stop Function..................................................................................................................... 370 Real-time Monitoring Function Of Transmission Controller.................................................................................... 371 Transmission Controller Self-Diagnosis Function............................................................................................. 371 Work Equipment Control System................................................................................................................... 372 Work Equipment Control System Diagram....................................................................................................... 372 Work Equipment Control Function............................................................................................................. 374 Work Equipment Neutral Lock Function........................................................................................................ 375 Neutral Position and Work Equipment Speed................................................................................................... 377 Bucket Priority Control..................................................................................................................... 378 Boom Stop Modulation........................................................................................................................ 378 Adjustment of Lever Detent Position and Work Equipment Starting Current..................................................................... 379 Swash Plate Control Function of Work Equipment Pump and Steering Pump....................................................................... 379 Overheat Prevention Function of Work Equipment Controller................................................................................... 383 Remote Positioner Function.................................................................................................................. 383 Semi Auto-Digging Function.................................................................................................................. 389 Electric Emergency Steering Function........................................................................................................ 392 Real-Time Monitoring Function of Work Equipment Controller.................................................................................. 393 Self-Diagnosis Function of Work Equipment Controller........................................................................................ 393 Machine Monitor System.......................................................................................................................... 394 Function.................................................................................................................................... 395 Details of Monitor Controller Network Signals............................................................................................... 395 Machine Monitor............................................................................................................................. 399 Switch Panel................................................................................................................................ 418 Rear View Monitor System.................................................................................................................... 420 Rear View Monitor........................................................................................................................... 420 Rear View Camera............................................................................................................................ 422 KOMTRAX System.................................................................................................................................. 423 KOMTRAX Terminal............................................................................................................................ 424 System Component Parts...................................................................................................................... 426 Work Equipment Controller................................................................................................................... 432 Transmission Controller..................................................................................................................... 436 Machine Controller.......................................................................................................................... 440 Work Equipment Electric Lever............................................................................................................... 446 Throttle Position Sensor.................................................................................................................... 448 Combination Switch.......................................................................................................................... 450 Kickdown Switch............................................................................................................................. 452 Hold Switch................................................................................................................................. 452 CAN Terminating Resistor.................................................................................................................... 453 Specifications.............................................................................................................................. 453 Engine Oil Pressure Switch.................................................................................................................. 454 Specifications.............................................................................................................................. 454 Front Brake Oil Pressure Switch............................................................................................................. 454 Specification............................................................................................................................... 454 Rear Brake Oil Pressure Switch.............................................................................................................. 455 Specification............................................................................................................................... 455 Stop Lamp Oil Pressure Switch............................................................................................................... 455 Specification............................................................................................................................... 455 Parking Brake Oil Pressure Switch........................................................................................................... 456 Specification............................................................................................................................... 456 SENSORS............................................................................................................................................. 458 Ambient Pressure Sensor......................................................................................................................... 458 Function.................................................................................................................................... 458 Coolant Temperature Sensor...................................................................................................................... 458 Function.................................................................................................................................... 459 Ne (Crankshaft) Speed Sensor.................................................................................................................... 459 Bkup (Camshaft) Speed Sensor.................................................................................................................... 459 Function.................................................................................................................................... 459 Common Rail Pressure Sensor..................................................................................................................... 460 Function.................................................................................................................................... 460 Exhaust Manifold Pressure Sensor................................................................................................................ 460 Function.................................................................................................................................... 460 EGR Orifice Temperature Sensor.................................................................................................................. 461 EGR Valve Lift Sensor........................................................................................................................... 461 Function.................................................................................................................................... 461 KVGT Speed Sensor............................................................................................................................... 462 Function.................................................................................................................................... 462 KVGT Position Sensor............................................................................................................................ 463 Function.................................................................................................................................... 463 Output characteristics...................................................................................................................... 463 Mass Air Flow and Temperature Sensor............................................................................................................ 464 Function.................................................................................................................................... 464 KDPF Differential Pressure and Outlet Pressure Sensor........................................................................................... 464 Function.................................................................................................................................... 464 KDOC Inlet Temperature Sensor................................................................................................................... 465 Function.................................................................................................................................... 465 KDOC Outlet Temperature Sensor.................................................................................................................. 465 Function.................................................................................................................................... 465 KDPF Outlet Temperature Sensor.................................................................................................................. 466 Function.................................................................................................................................... 466 Crankcase Pressure Sensor....................................................................................................................... 466 Function.................................................................................................................................... 466 Engine Oil Level Sensor......................................................................................................................... 467 Function.................................................................................................................................... 467 Transmission Input Speed Sensor................................................................................................................. 467 Function.................................................................................................................................... 467 Transmission Output Shaft Speed Sensor.......................................................................................................... 468 Function.................................................................................................................................... 468 Cooling Fan Speed Sensor........................................................................................................................ 468 Function.................................................................................................................................... 468 Torque Converter Oil Temperature Sensor......................................................................................................... 469 Function.................................................................................................................................... 469 Transmission Oil Temperature Sensor............................................................................................................. 469 Function.................................................................................................................................... 469 Hydraulic Oil Temperature Sensor................................................................................................................ 470 Function.................................................................................................................................... 470 Brake Oil Temperature Sensor.................................................................................................................... 470 Function.................................................................................................................................... 470 Transmission Inlet Pressure Sensor.............................................................................................................. 471 Function.................................................................................................................................... 471 Output characteristics...................................................................................................................... 471 Transmission Outlet Pressure Sensor............................................................................................................. 472 Function.................................................................................................................................... 472 Output characteristics...................................................................................................................... 472 Oil Pressure Sensor of Work Equipment Pump...................................................................................................... 473 Function.................................................................................................................................... 473 Output characteristics...................................................................................................................... 473 Steering Pump Oil Pressure Sensor............................................................................................................... 473 Function.................................................................................................................................... 473 Output characteristics...................................................................................................................... 474 Emergency Steering Pump Pressure Sensor......................................................................................................... 474 Function.................................................................................................................................... 474 Output characteristics...................................................................................................................... 474 Boom Cylinder Bottom Oil Pressure Sensor........................................................................................................ 475 Function.................................................................................................................................... 475 Output characteristics...................................................................................................................... 475 Transmission Cut-off Oil Pressure Sensor........................................................................................................ 476 Function.................................................................................................................................... 476 Output characteristics...................................................................................................................... 476 Coolant Level Sensor............................................................................................................................ 477 Function.................................................................................................................................... 477 Fuel Level Sensor............................................................................................................................... 478 Function.................................................................................................................................... 478 Air Cleaner Clogging Sensor..................................................................................................................... 479 Function.................................................................................................................................... 479 Water-in-Fuel Sensor............................................................................................................................ 479 Function.................................................................................................................................... 479 Boom Potentiometer.............................................................................................................................. 480 Function.................................................................................................................................... 480 Output characteristics...................................................................................................................... 480 Bucket Potentiometer Sensor..................................................................................................................... 481 Function.................................................................................................................................... 481 Output characteristics...................................................................................................................... 481 QUICK COUPLER....................................................................................................................................... 482 Quick Coupler Switch............................................................................................................................ 482 Quick Coupler Solenoid Valve.................................................................................................................... 483 Outline......................................................................................................................................... 483 20 STANDARD VALUE TABLES................................................................................................................................ 485 STANDARD VALUE TABLES............................................................................................................................... 486 Service Value For Engine........................................................................................................................ 486 Service Values For Chassis...................................................................................................................... 488 Directional Levers.......................................................................................................................... 488 Gear Speed Switch........................................................................................................................... 488 Work Equipment Levers....................................................................................................................... 489 Multi-Function Mono-Lever................................................................................................................... 490 Steering Wheel.............................................................................................................................. 491 Frame....................................................................................................................................... 491 Accelerator Pedal........................................................................................................................... 492 Brake Pedal................................................................................................................................. 492 Tires....................................................................................................................................... 492 Engine Speed................................................................................................................................ 493 Transmission and Torque Converter........................................................................................................... 493 Steering.................................................................................................................................... 494 Accumulator................................................................................................................................. 494 Power Train................................................................................................................................. 494 Wheel Brake................................................................................................................................. 496 Parking Brake............................................................................................................................... 497 PPC......................................................................................................................................... 497 Work Equipment.............................................................................................................................. 498 Hydraulic Fan............................................................................................................................... 499 Machine Posture................................................................................................................................. 500 30 TESTING AND ADJUSTING................................................................................................................................ 503 TOOLS............................................................................................................................................... 508 Tools for Testing, Adjusting, and Troubleshooting............................................................................................... 508 Sketch of Tools for Testing and Adjusting....................................................................................................... 514 ENGINE AND COOLING SYSTEM........................................................................................................................... 516 Measuring Engine Speed.......................................................................................................................... 516 Measurement Conditions...................................................................................................................... 516 Testing..................................................................................................................................... 516 Measuring Boost Pressure........................................................................................................................ 518 Measuring With Machine Monitor.............................................................................................................. 518 Measuring by Use of Testing Tools........................................................................................................... 518 Testing Exhaust Gas Temperatures................................................................................................................ 520 Testing..................................................................................................................................... 520 Testing Exhaust Gas Color....................................................................................................................... 524 Testing..................................................................................................................................... 524 Testing and Adjusting Valve Clearance........................................................................................................... 528 Testing..................................................................................................................................... 528 Adjusting................................................................................................................................... 530 Measuring Compression Pressure.................................................................................................................. 532 Testing..................................................................................................................................... 532 Measuring Blow-By Pressure...................................................................................................................... 538 Measuring Engine Oil Pressure................................................................................................................... 540 Measuring EGR Valve and KVGT Oil Pressure....................................................................................................... 542 Testing..................................................................................................................................... 542 Testing Fuel Pressure........................................................................................................................... 544 Testing..................................................................................................................................... 545 Testing Low-Pressure Circuit (Pressure Difference).......................................................................................... 546 Testing Return Circuit...................................................................................................................... 547 Testing Negative-Pressure Circuit........................................................................................................... 548 Measuring Fuel Delivery, Return and Leakage..................................................................................................... 550 Testing..................................................................................................................................... 551 Testing Supply Pump Return Rate............................................................................................................. 552 Testing Leakage from Pressure Limiter....................................................................................................... 554 Testing Fuel Return Rate from Injector...................................................................................................... 555 Bleeding Air from Fuel System............................................................................................................... 556 Checking Fuel Circuit for Leakage............................................................................................................... 558 Handling Cylinder Cut-Out Mode Operation........................................................................................................ 559 Handling No-Injection Cranking Operation........................................................................................................ 559 Check of KDPF and Muffler Stack for Looseness and Damage.................................................................................... 559 Check of Installed Condition of Cylinder Head and Manifolds................................................................................. 559 Checking Engine Piping for Damage and Looseness............................................................................................. 559 Testing and Adjusting Air Conditioner Compressor Belt Tension............................................................................... 560 Replacing Alternator Belt................................................................................................................... 561 POWER TRAIN SYSTEM.................................................................................................................................. 562 Adjusting Transmission Output Speed Sensor...................................................................................................... 562 Adjustment.................................................................................................................................. 562 Adjusting Transmission Input Speed Sensor....................................................................................................... 563 Adjustment.................................................................................................................................. 563 Flushing Procedure for Torque Converter and Transmission Hydraulic Circuit...................................................................... 564 Flushing Procedures......................................................................................................................... 564 Retrieval of Disabled Machine Due to Transmission Valve Failure................................................................................. 566 How to Move................................................................................................................................. 566 Checking Oil Leakage from Axle Final Drive.................................................................................................. 567 Checking Drive Shaft for Looseness, Play, and Damage........................................................................................ 568 Testing and Adjusting Power Train Oil Pressure.................................................................................................. 570 Testing..................................................................................................................................... 574 Adjustment.................................................................................................................................. 587 STEERING SYSTEM..................................................................................................................................... 588 Checking Directional Lever...................................................................................................................... 588 Testing..................................................................................................................................... 588 Testing Steering Wheel.......................................................................................................................... 590 Testing..................................................................................................................................... 590 Testing Work Equipment Control Lever............................................................................................................ 592 Testing..................................................................................................................................... 592 Testing and Adjusting Steering Circuit Pressure................................................................................................. 594 Testing..................................................................................................................................... 594 Adjustment.................................................................................................................................. 596 Bleeding Air from Steering Cylinder Circuit..................................................................................................... 597 Bleeding Air................................................................................................................................ 597 Testing and Adjusting Steering Stopper Valve.................................................................................................... 598 Testing..................................................................................................................................... 598 Adjustment.................................................................................................................................. 598 BRAKE SYSTEM........................................................................................................................................ 600 Testing Brake Pedal............................................................................................................................. 600 Testing..................................................................................................................................... 600 Testing and Adjusting Brake Pedal Linkage....................................................................................................... 601 Testing..................................................................................................................................... 601 Adjustment.................................................................................................................................. 601 Testing Braking Performance..................................................................................................................... 602 Testing..................................................................................................................................... 602 Testing and Adjusting Accumulator Charge Pressure............................................................................................... 604 Testing..................................................................................................................................... 604 Adjusting................................................................................................................................... 605 Testing Wheel Brake Oil Pressure................................................................................................................ 606 Testing..................................................................................................................................... 606 Measuring Lowering of Wheel Brake Pressure...................................................................................................... 608 Testing..................................................................................................................................... 608 Brake Test Kit.............................................................................................................................. 610 Measuring Wear of Wheel Brake Disc.............................................................................................................. 611 Testing..................................................................................................................................... 611 Bleeding Air From Wheel Brake Circuit........................................................................................................... 612 Bleeding Air................................................................................................................................ 612 Releasing Remaining Pressure in Brake Accumulator Circuit....................................................................................... 613 Releasing Remaining Pressure................................................................................................................ 613 Testing Parking Brake Performance............................................................................................................... 613 Testing..................................................................................................................................... 613 Testing Parking Brake Oil Pressure.............................................................................................................. 614 Testing..................................................................................................................................... 614 Testing Wear of Parking Brake Disc.............................................................................................................. 616 Testing..................................................................................................................................... 616 Method of Releasing Parking Brake Manually...................................................................................................... 618 How to Release.............................................................................................................................. 618 HYDRAULIC SYSTEM.................................................................................................................................... 620 Checking Fan Speed.............................................................................................................................. 620 Testing..................................................................................................................................... 620 Measuring Fan Pump Circuit Oil Pressure......................................................................................................... 622 Testing..................................................................................................................................... 622 Bleeding Air from Hydraulic Fan Circuit......................................................................................................... 624 Bleeding Air................................................................................................................................ 624 Testing and Adjusting Work Equipment PPC Oil Pressure........................................................................................... 626 Testing..................................................................................................................................... 626 Adjustment.................................................................................................................................. 628 Testing and Adjusting Work Equipment Oil Pressure............................................................................................... 630 Preparation................................................................................................................................. 630 Testing..................................................................................................................................... 631 Bleeding Air from Work Equipment Circuit........................................................................................................ 634 Bleeding Air from Work Equipment Pump (Piston Pump)......................................................................................... 634 Bleeding Air from Cylinder.................................................................................................................. 634 Releasing Remaining Pressure from Work Equipment Circuit........................................................................................ 636 Releasing Remaining Pressure Between Each Hydraulic Cylinder and Control Valve.............................................................. 636 Releasing Remaining Pressure In ECSS Circuit................................................................................................ 636 Checking of ECSS Accumulator Nitrogen Gas Pressure and Procedure for Charging Accumulator with Nitrogen Gas..................................... 638 Testing Nitrogen Gas Pressure in Accumulator................................................................................................ 638 Procedure for Charging Accumulator with Nitrogen Gas............................................................................................ 641 WORK EQUIPMENT...................................................................................................................................... 646 Testing and Adjusting Bucket Position Detection Lever........................................................................................... 646 Testing..................................................................................................................................... 646 Adjustment.................................................................................................................................. 646 Testing and Adjusting Boom Position Detection Lever............................................................................................. 647 Testing..................................................................................................................................... 647 Adjustment.................................................................................................................................. 647 ELECTRICAL SYSTEM................................................................................................................................... 648 Adjusting Replaced, Reassembled or Added Sensor, Controller, Etc. with Machine Monitor.......................................................... 648 Special Functions of Machine Monitor............................................................................................................ 650 Ordinary Functions and Special Functions of Machine Monitor................................................................................. 651 Operator Mode (outline)..................................................................................................................... 653 Service Mode................................................................................................................................ 666 Angle Adjustment of Rear View Camera............................................................................................................ 760 Adjustment.................................................................................................................................. 761 Handling Voltage Circuit of Engine Controller............................................................................................... 761 Handling Battery Disconnect Switch.............................................................................................................. 762 Testing Diodes.................................................................................................................................. 763 Testing..................................................................................................................................... 763 PM-CLINIC INSPECTION TABLE.......................................................................................................................... 764 Check Sheet..................................................................................................................................... 765 40 TROUBLESHOOTING...................................................................................................................................... 771 POINTS TO REMEMBER WHEN TROUBLESHOOTING............................................................................................................. 784 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE........................................................................................................... 787 Precautions when Handling Electrical Equipment.................................................................................................. 787 Handling Electronic Control Unit................................................................................................................ 792 Points to Remember when Troubleshooting Electrical Circuits..................................................................................... 793 ELECTRIC WIRE CODE.................................................................................................................................. 794 Classification by Thickness..................................................................................................................... 794 Classification by Color and Code................................................................................................................ 794 How to Read Electric Wire Code.................................................................................................................. 795 Type, Symbol, and Material.................................................................................................................. 795 Dimensions.................................................................................................................................. 796 HANDLING HYDRAULIC EQUIPMENT........................................................................................................................ 797 CHECKS BEFORE TROUBLESHOOTING....................................................................................................................... 799 Testing Procedure Before Troubleshooting........................................................................................................ 801 Walk-Around Check........................................................................................................................... 801 Categories and Method of Using Troubleshooting Charts........................................................................................... 809 Information Mentioned in Troubleshooting Table.................................................................................................. 812 Connector List.................................................................................................................................. 814 Layout of Connectors (1/7)...................................................................................................................... 828 Layout of Connectors (2/7)...................................................................................................................... 829 Layout of Connectors (3/7)...................................................................................................................... 830 Layout of Connectors (4/7)...................................................................................................................... 831 Layout of Connectors (5/7)...................................................................................................................... 832 Layout of Connectors (6/7)...................................................................................................................... 833 Layout of Connectors (7/7)...................................................................................................................... 834 Diagnostic Procedure for Wiring Harness Open Circuit of Pressure Sensor System.................................................................. 836 Fuse Location Table............................................................................................................................. 839 Precautions for Cleaning and Replacing KDPF (KCSF, KDOC)........................................................................................ 842 Dummy Temperature Sensor (for KDOC and KDPF Temperature Sensors)................................................................................ 846 Short-Circuit Connector (for CA1883 and CA3135)................................................................................................. 847 Precautions on Troubleshooting of Machine Monitor............................................................................................... 848 Processing Procedure of Harness Checker for Troubleshooting of Machine Monitor LCD Unit......................................................... 850 TROUBLESHOOTING BY FAILURE CODE..................................................................................................................... 856 Failure Code Table.............................................................................................................................. 856 FAILURE CODES....................................................................................................................................... 868 [1500L0] Double Engagement of T/M Clutches...................................................................................................... 868 [15SAL1] Release Trouble of ECMV (Forward)...................................................................................................... 870 [15SALH] Malfunction of ECMV (Forward).......................................................................................................... 872 [15SBL1] Release Trouble of ECMV (Release)...................................................................................................... 874 [15BLH] Malfunction of ECMV (Reverse)........................................................................................................... 876 [15SEL1] Release Trouble of ECMV (1st).......................................................................................................... 878 [15SELH] Malfunction of ECMV (1st).............................................................................................................. 880 [15SFL1] Release Trouble of ECMV (2nd).......................................................................................................... 882 [15SFLH] Malfunction of ECMV (2nd).............................................................................................................. 884 [15SGL1] Release Trouble of ECMV (3rd).......................................................................................................... 886 [15SGLH] Malfunction of ECMV (3rd).............................................................................................................. 888 [15SHL1] Release Trouble of ECMV (4th).......................................................................................................... 890 [15SHLH] Malfunction of ECMV (4th).............................................................................................................. 892 [2F00MA] Failure of Parking Brake Circuit....................................................................................................... 894 [2G42ZG] Accumulator Oil Pressure Low (Front)................................................................................................... 898 [2G43ZG] Accumulator Oil Pressure Low (Rear).................................................................................................... 900 [879AKA] A/C Inner Sensor Open Circuit.......................................................................................................... 902 [879AKB] A/C Inner Sensor Short Circuit......................................................................................................... 904 [879BKA] A/C Outer Sensor Open Circuit.......................................................................................................... 906 [879BKB] A/C Outer Sensor Short Circuit......................................................................................................... 908 [879CKA] Ventilating Sensor Open Circuit........................................................................................................ 910 [879CKB] Ventilating Sensor Short Circuit....................................................................................................... 912 [879DKZ] Sunlight Sensor Open or Short Circuit.................................................................................................. 914 [879EMC] Ventilation Damper Abnormality......................................................................................................... 916 [879FMC] Air Mix Damper Abnormality............................................................................................................. 919 [989A00] Engine Overrun Protection Activated.................................................................................................... 922 [989L00] Engine Controller Lock Caution 1....................................................................................................... 922 [989M00] Engine Controller Lock Caution 2....................................................................................................... 923 [989N00] Engine Controller Lock Caution 3....................................................................................................... 923 [A1U0N3] HC Desorb Request 1.................................................................................................................... 924 [A1U0N4] HC Desorb Request 2.................................................................................................................... 926 [AA10NX] Air Cleaner Clogging................................................................................................................... 928 [B@BAZG] Eng Oil Press Low...................................................................................................................... 930 [B@BAZK] Eng Oil Level Low...................................................................................................................... 932 [B@BCNS] Eng Water Overheat..................................................................................................................... 934 [B@BCZK] Eng Water Level Low.................................................................................................................... 936 [B@CENS] T/C Oil Temp. Overheat................................................................................................................. 938 [B@HANS] HYD Oil Temp. Overheat................................................................................................................. 939 [CA115] Eng Ne and Bkup Speed Sens Error........................................................................................................ 939 [CA122] Chg Air Press Sensor High Error......................................................................................................... 940 [CA123] Chg Air Press Sensor Low Error.......................................................................................................... 942 [CA131] Throttle Sensor High Error.............................................................................................................. 944 [CA132] Throttle Sensor Low Error............................................................................................................... 946 [CA144] Coolant Temp Sens High Error............................................................................................................ 948 [CA145] Coolant Temp Sens Low Error............................................................................................................. 950 [CA153] Chg Air Temp Sensor High Error.......................................................................................................... 952 [CA154] Chg Air Temp Sensor High Error.......................................................................................................... 954 [CA187] Sensor 2 Supply Volt Low Error.......................................................................................................... 956 [CA221] Ambient Press Sensor High Error......................................................................................................... 958 [CA222] Ambient Press Sensor Low Error.......................................................................................................... 960 [CA227] Sensor 2 Supply Volt High Error......................................................................................................... 963 [CA234] Eng Overspeed........................................................................................................................... 963 [CA238] Ne Speed Sensor Supply Volt Error....................................................................................................... 964 [CA239] Ne Speed Sens Supply Volt High Error.................................................................................................... 966 [CA271] IMV/PCV1 Short Error.................................................................................................................... 968 [CA272] IMV/PCV1 Open Error..................................................................................................................... 970 [CA295] Ambient Press Sens In Range Error....................................................................................................... 972 [CA322] Inj #1 (L#1) Open/Short Error........................................................................................................... 973 [CA323] Inj #5 (L#5) Open/Short Error........................................................................................................... 975 [CA324] Inj #3 (L#3) Open/Short Error........................................................................................................... 977 [CA325] Inj #6 (L#6) Open/Short Error........................................................................................................... 979 [CA331] Inj #2 (L#2) Open/Short Error........................................................................................................... 981 [CA332] Inj #4 (L#4) Open/Short Error........................................................................................................... 983 [CA343] ECM Critical Internal Failure........................................................................................................... 985 [CA351] Injectors Drive Circuit Error........................................................................................................... 985 [CA352] Sensor 1 Supply Volt Low Error.......................................................................................................... 986 [CA356] Mass Air Flow Sensor High Error......................................................................................................... 988 [CA357] Mass Air Flow Sensor Low Error.......................................................................................................... 990 [CA386] Sensor 1 Supply Volt High Error......................................................................................................... 993 [CA428] Water in Fuel Sensor High Error......................................................................................................... 994 [CA429] Water in Fuel Sensor Low Error.......................................................................................................... 996 [CA431] Idle Validation Switch Error............................................................................................................ 998 [CA432] Idle Validation Process Error...........................................................................................................1002 [CA435] Eng Oil Press Sw Error..................................................................................................................1006 [CA441] Battery Voltage Low Error...............................................................................................................1008 [CA442] Battery Voltage High Error..............................................................................................................1010 [CA449] Rail Press Very High Error..............................................................................................................1011 [CA451] Rail Press Sensor High Error............................................................................................................1012 [CA452] Rail Press Sensor Low Error.............................................................................................................1014 [CA488] Chg Air Temp High Torque Derate.........................................................................................................1016 [CA515] Rail Press Sens Sup Volt High Error.....................................................................................................1018 [CA516] Rail Press Sens Sup Volt Low Error......................................................................................................1020 [CA553] Rail Press High Error...................................................................................................................1022 [CA555] Crankcase Press High Error 1............................................................................................................1022 [CA556] Crankcase Press High Error 2............................................................................................................1023 [CA559] Rail Press Low Error....................................................................................................................1024 [CA595] Turbo Speed High Error 2................................................................................................................1025 [CA687] Turbo Speed Low Error...................................................................................................................1026 [CA689] Eng Ne Speed Sensor Error...............................................................................................................1028 [CA691] Intake Air Temp Sens High Error.........................................................................................................1032 [CA692] Intake Air Temp Sens Low Error..........................................................................................................1034 [CA697] ECM Int Temp Sensor High Error..........................................................................................................1036 [CA698] ECM Int Temp Sensor Low Error...........................................................................................................1037 [CA731] Eng Bkup Speed Sens Phase Error.........................................................................................................1038 [CA778] Eng Bkup Speed Sensor Error.............................................................................................................1040 [CA1117] Persistent Data Lost Error.............................................................................................................1044 [CA1664] KDOC Malfunction.......................................................................................................................1045 [CA1691] Regeneration Ineffective...............................................................................................................1048 [CA1695] Sensor 5 Supply Volt High Error........................................................................................................1052 [CA1696] Sensor 5 Supply Volt Low Error.........................................................................................................1054 [CA1843] Crankcase Press Sens High Error........................................................................................................1056 [CA1844] Crankcase Press Sens Low Error.........................................................................................................1058 [CA1879] KDPF Delta P Sensor High Error.........................................................................................................1060 [CA1881] KDPF Delta P Sensor Low Error..........................................................................................................1062 [CA1883] KDPF Delta P Sens In Range Error.......................................................................................................1064 [CA1921] KDPF Soot Load High Error 1............................................................................................................1070 [CA1922] KDPF Soot Load High Error 2............................................................................................................1072 [CA1942] Crankcase Press Sens In Range Error....................................................................................................1076 [CA1993] KDPF Delta Pressure Low Error..........................................................................................................1077 [CA2185] Throt Sensor Sup Volt High Error.......................................................................................................1080 [CA2186] Throt Sensor Sup Volt Low Error........................................................................................................1082 [CA2249] Rail Press Very Low Error..............................................................................................................1083 [CA2271] EGR Valve Pos Sens High Error..........................................................................................................1084 [CA2272] EGR Valve Pos Sens Low Error...........................................................................................................1088 [CA2288] Turbo Speed High Error 1...............................................................................................................1092 [CA2311] IMV Solenoid Error.....................................................................................................................1092 [CA2349] EGR Valve Solenoid Open Error..........................................................................................................1094 [CA2353] EGR Valve Solenoid Short Error.........................................................................................................1096 [CA2357] EGR Differential Pressure..............................................................................................................1098 [CA2373] Exh Manifold Press. Sens High Error....................................................................................................1100 [CA2374] Exhaust Manifold Press Sens Low Error..................................................................................................1102 [CA2375] EGR Orifice Temp Sens High Error.......................................................................................................1104 [CA2376] EGR Orifice Temp Sens Low Error........................................................................................................1106 [CA2381] KVGT Pos Sens High Error...............................................................................................................1108 [CA2382] KVGT Pos Sens Low Error................................................................................................................1110 [CA2383] KVGT Solenoid Open Error...............................................................................................................1114 [CA2386] KVGT Solenoid Short Error..............................................................................................................1116 [CA2387] KVGT Servo Error.......................................................................................................................1118 [CA2554] Exh Manifold Press Sens In Range Error.................................................................................................1119 [CA2555] Grid Htr Relay Volt Low Error..........................................................................................................1120 [CA2556] Grid Htr Relay Volt High Error.........................................................................................................1122 [CA2637] KDOC Face Plugging.....................................................................................................................1124 [CA2639] Manual Stationary Regeneration Request.................................................................................................1126 [CA2961] EGR Orifice Temp High Error 1..........................................................................................................1128 [CA2973] Chg Air Press Sensor In Range Error....................................................................................................1129 [CA3133] KDPF Outlet Press Sens High Error......................................................................................................1130 [CA3134] KDPF Outlet Press Sens Low Error.......................................................................................................1132 [CA3135] KDPF Outlet Press Sens In Range Error..................................................................................................1134 [CA3251] KDOC Inlet Temp High Error.............................................................................................................1139 [CA3253] KDOC Temp Error - Non Regeneration.....................................................................................................1142 [CA3254] KDOC Outlet Temp High Error 1..........................................................................................................1146 [CA3255] KDPF Temp Error - Non Regeneration.....................................................................................................1150 [CA3256] KDPF Outlet Temp High Error 1..........................................................................................................1154 [CA3311] KDOC Outlet Temp High Error 2..........................................................................................................1158 [CA3312] KDPF Outlet Temp High Error 2..........................................................................................................1162 [CA3313] KDOC Inlet Temp Sensor Low Error.......................................................................................................1166 [CA3314] KDOC Inlet Temp Sens High Error........................................................................................................1170 [CA3315] KDOC Inlet Temp Sens In Range Error....................................................................................................1174 [CA3316] KDOC Outlet Temp Sens Low Error........................................................................................................1180 [CA3317] KDOC Outlet Temp Sens High Error.......................................................................................................1184 [CA3318] KDOC Inlet Temp Sens In Range Error....................................................................................................1188 [CA3319] KDPF Outlet Temp Sens High Error.......................................................................................................1194 [CA3321] KDPF Outlet Temp Sens Low Error........................................................................................................1198 [CA3322] KDPF Outlet Temp Sens In Range Error...................................................................................................1202 [CA3419] Mass Air Flow Sensor Sup Volt High Error...............................................................................................1208 [CA3421] Mass Air Flow Sensor Sup Volt Low Error................................................................................................1210 [CA3741] Rail Press Valve Trip Error............................................................................................................1212 [D150KA] Disconnection of Emergency Steering Relay..............................................................................................1214 [D150KB] Ground Fault of Emergency Steering Relay...............................................................................................1216 [D150KY] Hot Short of Emergency Steering Relay..................................................................................................1218 [D160KA] Disconnection of Back-Up Lamp Relay Output.............................................................................................1220 [D160KB] Ground Fault of Back-Up Lamp Relay Output..............................................................................................1222 [D160KY] Hot Short of Back-Up Lamp Relay Output.................................................................................................1224 [D191KA] Disconnection of Neutral Output Relay..................................................................................................1226 [D191KB] Ground Fault of Neutral Output Relay...................................................................................................1230 [D191KY] Hot Short of Neutral Output Relay......................................................................................................1234 [D192KA] Disconnection of ECSS Solenoid.........................................................................................................1236 [D192KB] Ground Fault of ECSS Solenoid..........................................................................................................1238 [D192KY] Hot Short of ECSS Solenoid.............................................................................................................1240 [D19JKZ] Personal Code Relay Abnormality........................................................................................................1242 [D1E6KA] Disconnection of Parking Brake Relay...................................................................................................1244 [D1E6KB] Ground Fault of Parking Brake Relay....................................................................................................1246 [D1E6KY] Hot Short of Parking Brake Relay.......................................................................................................1248 [D5ZHKA] Failure of Key SW C Signal.............................................................................................................1250 [D5ZHKB] Key SW C Signal Short Circuit..........................................................................................................1252 [D5ZHKZ] Failure of Key SW C Signal.............................................................................................................1254 [D5ZHL6] Disconnection of Key SW C..............................................................................................................1258 [D811MC] KOMTRAX Error..........................................................................................................................1260 [D862KA] GPS Antenna Open Circuit...............................................................................................................1260 [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)..................................................................................................1262 [D8ALKB] Operating Lamp Short Circuit (KOMTRAX).................................................................................................1264 [D8AQK4] CAN2 Discon (KOMTRAX) 2................................................................................................................1266 [D8AQKR] CAN2 Discon (KOMTRAX)..................................................................................................................1267 [DAF0KT] Abnormality of Non-volatile Memory (MON)...............................................................................................1268 [DAF0MB] Monitor ROM Abnormality................................................................................................................1268 [DAF0MC] Monitor Error..........................................................................................................................1268 [DAF3KK] Controller Power Source Low (MON)......................................................................................................1270 [DAF8KB] Camera Power Supply Short Circuit......................................................................................................1272 [DAFDKB] Monitor 12 V Power Output Short Circuit................................................................................................1274 [DAFGMC] GPS Module Error.......................................................................................................................1275 [DAFLKA] Operating Lamp Open Circuit (MON)......................................................................................................1276 [DAFLKB] Operating Lamp Short Circuit (MON).....................................................................................................1278 [DAFQKR] CAN2 Discon (Monitor)..................................................................................................................1280 [DAQ0KK] Controller Power Source Low (T/M)......................................................................................................1282 [DAQ0KT] Abnormality of Non-volatile Memory (T/M)...............................................................................................1286 [DAQ0MC] T/M Con Error..........................................................................................................................1287 [DAQ1KA] Disconnection of Key SWACC (T/M).......................................................................................................1288 [DAQ2KK] Solenoid Power Source Low (T/M)........................................................................................................1290 [DAQ4KB] Ground Fault of Sol. Self-Holding Relay (TM)...........................................................................................1294 [DAQ9KQ] Inconsistency of Model Selection (T/M).................................................................................................1296 [DAQLKA] Operating Lamp Open Circuit (T/M)......................................................................................................1298 [DAQLKB] Operating Lamp Short Circuit (T/M).....................................................................................................1300 [DAQQKR] CAN2 Discon (Transmission Con).........................................................................................................1302 [DAQRKR] CAN1 Discon (Transmission Con).........................................................................................................1303 [DAQRMA] Inconsistency of Option Selection (T/M)................................................................................................1304 [DAZ9KQ] A/C Model Selection Abnormality........................................................................................................1304 [DAZQKR] CAN2 Discon (Aircon ECU)...............................................................................................................1305 [DB2QKR] CAN2 Discon (Engine Con)...............................................................................................................1306 [DB2RKR] CAN1 Discon (Engine Con)...............................................................................................................1312 [DB90KK] Drop in BBC Controller Main Power Source...............................................................................................1318 [DB90KT] Abnormality of Non-Volatile Memory (BBC)...............................................................................................1320 [DB90MC] BBC Error..............................................................................................................................1320 [DB91KA] Disconnection of Key SW ACC (BBC)......................................................................................................1322 [DB92KK] Solenoid Power Source Low (BBC)........................................................................................................1324 [DB95KX] Failure of 5 V Power Source 1..........................................................................................................1328 [DB96KX] Failure of 5 V Power Source 2..........................................................................................................1332 [DB99KQ] Inconsistency of Model Selection (BBC).................................................................................................1334 [DB9LKA] Operating Lamp Open Circuit (BBC)......................................................................................................1336 [DB9LKB] Operating Lamp Short Circuit (BBC).....................................................................................................1338 [DB9QKR] CAN2 Discon (Bucket Boom Con)..........................................................................................................1340 [DB9RKR] CAN1 Discon (Bucket Boom Con)..........................................................................................................1341 [DB9RMA] Inconsistency of Option Selection (BBC)................................................................................................1342 [DBE5KX] Failure of 5 V Power Source............................................................................................................1344 [DBE6KX] Failure of 24 V Power Source...........................................................................................................1346 [DD1ALD] Ground Fault of Remote Positioner Set SW...............................................................................................1348 [DDAAL6] Disconnection of Secondary Switch ENG Stop SW..........................................................................................1350 [DDB6L4] Neutral Signal Malfunction.............................................................................................................1352 [DDD1LD] Failure of Bucket Positioner Set Switch................................................................................................1356 [DDK3KA] FNR SW Input Signal Disconnection......................................................................................................1358 [DDK3KB] FNR SW Input Signal Short Circuit......................................................................................................1362 [DDK6KA] FNR Lever Input Signal Disconnection...................................................................................................1364 [DDK6KB] FNR Lever Input Signal Short Circuit...................................................................................................1368 [DDNRKY] Hot Short of Work Equipment Lock SW....................................................................................................1370 [DDT0L4] Failure of Shift Mode Select SW........................................................................................................1372 [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal..............................................................................................1374 [DDT9LD] Ground Fault of T/M Cut Off Set SW Signal..............................................................................................1376 [DDW9LD] Ground Fault of Kick-Down Switch.......................................................................................................1378 [DDWLLD] Ground Fault of T/M Shift Hold SW......................................................................................................1380 [DF10KA] Disconnection of Shift Lever Input.....................................................................................................1382 [DF10KB] Ground Fault of Shift Lever Input......................................................................................................1386 [DGF1KA] Disconnection of T/M Oil Temp Sensor...................................................................................................1390 [DGF1KB] Ground Fault of T/M Oil Temp. Sensor...................................................................................................1392 [DGH2KX] Out of Range of HYD Oil Temp. Sensor...................................................................................................1394 [DGR2KB] Ground Fault of Brake Oil Temp. Sensor.................................................................................................1396 [DGR2KZ] Failure of Brake Oil Temp. Sensor......................................................................................................1398 [DGT1KA] Disconnection of T/C Oil Temp. Sensor..................................................................................................1400 [DGT1KB] Ground Fault of T/C Oil Temp. Sensor...................................................................................................1402 [DH21KA] Failure of Loader Pump Press. Sensor...................................................................................................1404 [DH21KB] Loader Pump Press. Sensor Short Circuit................................................................................................1408 [DHA4KA] Failure of Air Cleaner Sensor Circuit..................................................................................................1410 [DHPCKX] Out of Range of Boom Bottom Press. Sensor..............................................................................................1412 [DHPDKX] Out of Range of Boom Head Press. Sensor................................................................................................1414 [DHT1KX] Out of Range of T/M Cut Off Press. Sensor..............................................................................................1416 [DHT5KX] Out of Range of T/C Input Pressure Sensor..............................................................................................1418 [DHT7KX] Out of Range of T/C Output Pressure Sensor.............................................................................................1420 [DHT8KA] Failure of Steering Pump Press. Sensor.................................................................................................1422 [DHT8KB] Steering Pump Press. Sensor Short Circuit..............................................................................................1424 [DHT8ZG] Steering Oil Pressure Low..............................................................................................................1426 [DHUDKA] Failure of Emrg. Steering Press. Sensor................................................................................................1428 [DHUDKB] Emrg. Steering Press. S. Short Circuit.................................................................................................1432 [DJF1KA] Disconnection of Fuel Level Sensor.....................................................................................................1434 [DK55KA] Failure of FNR Lever Potentio..........................................................................................................1436 [DK55KY] Hot Short of FNR Lever Potentio Circuit................................................................................................1440 [DK55L5] Failure of FNR Lever Potentio..........................................................................................................1442 [DK59KA] Failure of Boom Lever Potentio (Main)..................................................................................................1443 [DK59KY] Hot Short of Boom Lever Potentio (Main)................................................................................................1446 [DK59L8] Boom Lever Potentio (Main & Sub) Disagree..............................................................................................1448 [DK5AKA] Failure of Boom Lever Potentio (Sub)...................................................................................................1452 [DK5AKY] Hot Short of Boom Lever Potentio (Sub).................................................................................................1456 [DK5BKA] Failure of Bucket Lever Potentio (Main)................................................................................................1460 [DK5BKY] Hot Short of Bucket Lever Potentio (Main)..............................................................................................1464 [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree..............................................................................................1468 [DK5CKA] Failure of Bucket Lever Potentio (Sub).................................................................................................1472 [DK5CKY] Hot Short of Bucket Lever Potentio (Sub)...............................................................................................1476 [DK5DKA] Failure of 3rd Lever Potentio (Main)...................................................................................................1480 [DK5DKY] Hot Short of 3rd Lever Potentio (Main).................................................................................................1484 [DK5DL8] 3rd Lever Potentio (Main&Sub) Disagree.................................................................................................1486 [DK5EKA] Failure of 3rd Lever Potentio (Sub)....................................................................................................1490 [DK5EKY] Hot Short of 3rd Lever Potentio (Sub)..................................................................................................1492 [DK5KKA] Failure of 4th Lever Potentio (Main)...................................................................................................1494 [DK5KKY] Hot Short of 4th Lever Potentio (Main).................................................................................................1496 [DK5KL8] 4th Lever Potentio (Main&Sub) Disagree.................................................................................................1498 [DK5LKA] Failure of 4th Lever Potentio (Sub)....................................................................................................1502 [DK5LKY] Hot Short of 4th Lever Potentio (Sub)..................................................................................................1504 [DKA0KA] Failure of Boom Angle Sensor...........................................................................................................1506 [DKA0KY] Hot Short of Boom Angle Sensor Circuit.................................................................................................1508 [DKA0L0] Boom Angle Sensor Dislocation..........................................................................................................1510 [DKA1KA] Failure of Bucket Angle Sensor.........................................................................................................1512 [DKA1KY] Hot Short of Bucket Angle Sensor Circuit...............................................................................................1514 [DLF1KA] Disconnection of T/M Input Speed Sensor................................................................................................1516 [DLF1LC] Failure of T/M Input Speed Sensor......................................................................................................1518 [DLM3KA] Disconnection of Radiator Fan Speed Sensor.............................................................................................1520 [DLM3LC] Failure of Radiator Fan Speed Sensor...................................................................................................1522 [DLT3KA] Disconnection of Output Speed Sens. (Main).............................................................................................1524 [DLT3LC] Failure of Output Speed Sensor (Main)..................................................................................................1526 [DPQ1KR] LIN Discon (Switch Panel)..............................................................................................................1528 [DPQ2KR] LIN Discon (LED Unit)..................................................................................................................1532 [DPQ3KR] LIN DIscon (Rear View Monitor).........................................................................................................1536 [DJS0KR] CAN2 Discon (Meter Unit)...............................................................................................................1540 [DT20KB] Ground Fault of T/M Cut Off Indicator..................................................................................................1542 [DT22KB] Ground Fault of Work Equip. Lock Indic.................................................................................................1544 [DV00KB] Ground Fault of Buzzer Output..........................................................................................................1546 [DW4PKA] Disconnection of Boom EPC Solenoid (Raise).............................................................................................1548 [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise)..............................................................................................1550 [DW4PKY] Hot Short of Boom EPC Solenoid (Raise).................................................................................................1552 [DW4QKA] Disconnection of Boom EPC Solenoid (Lower).............................................................................................1554 [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower)..............................................................................................1556 [DW4QKY] Hot Short of Boom EPC Solenoid (Lower).................................................................................................1558 [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt)................................................................................................1560 [DW4RKB] Ground Fault of Bucket EPC Sol. (Tilt).................................................................................................1562 [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt)................................................................................................1564 [DW4SKA] Disconnection of Bucket EPC. Sol (Dump)................................................................................................1566 [DW4SKB] Ground Fault of Bucket EPC Sol. (Dump).................................................................................................1568 [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump)................................................................................................1570 [DW7BKA] Disconnection of Fan Reverse Solenoid..................................................................................................1572 [DW7BKB] Ground Fault of Radiator Fan Reverse Solenoid..........................................................................................1574 [DW7BKY] Hot Short of Radiator Fan Rev. Sol.....................................................................................................1576 [DWM1KA] Disconnection of Neutral Lock Solenoid.................................................................................................1578 [DWM1KB] Ground Fault of Neutral Lock Solenoid..................................................................................................1580 [DWM1KY] Hot Short of Neutral Lock Solenoid.....................................................................................................1582 [DWN6KA] Disconnection of Detent Solenoid (Boom)................................................................................................1584 [DWN6KB] Ground Fault of Detent Solenoid (Boom).................................................................................................1586 [DWN6KY] Hot Short of Detent Solenoid (Boom)....................................................................................................1588 [DWN8KA] Disconnection of Detent Solenoid (Bucket)..............................................................................................1590 [DWN8KB] Ground Fault of Detent Solenoid (Bucket)...............................................................................................1592 [DWN8KY] Hot Short of Detent Solenoid (Bucket)..................................................................................................1594 [DX16KA] Disconnection of Radiator Fan Pump EPC Solenoid........................................................................................1596 [DX16KB] Ground Fault of Radiator Fan Pump EPC Solenoid.........................................................................................1598 [DX16KY] Hot Short of Radiator Fan Pump EPC Solenoid............................................................................................1600 [DXA1KA] Disconnection of Loader Pump EPC Solenoid..............................................................................................1602 [DXA1KB] Ground Fault of Loader Pump EPC Solenoid...............................................................................................1604 [DXA1KY] Hot Short of Loader Pump EPC Solenoid..................................................................................................1606 [DXANKA] Disconnection of Steering Pump EPC Solenoid............................................................................................1608 [DXANKB] Ground Fault of Steering Pump EPC Solenoid.............................................................................................1610 [DXANKY] Hot Short of Steering Pump EPC Solenoid................................................................................................1612 [DXH1KA] Disconnection of ECMV Solenoid (Lockup)................................................................................................1614 [DXH1KB] Ground Fault of ECMV Solenoid (Lockup).................................................................................................1616 [DXH1KY] Hot Short of ECMV Solenoid (Lockup)....................................................................................................1618 [DXH4KA] Disconnection of ECMV Solenoid (1st)...................................................................................................1620 [DXH4KB] Ground Fault of ECMV Solenoid (1st)....................................................................................................1622 [DXH4KY] Hot Short of ECMV Solenoid (1st).......................................................................................................1624 [DXH5KA] Disconnection of ECMV Solenoid (2nd)...................................................................................................1626 [DXH5KB] Ground Fault of ECMV Solenoid (2nd)....................................................................................................1628 [DXH5KY] Hot Short of ECMV Solenoid (2nd).......................................................................................................1630 [DXH6KA] Disconnection of ECMV Solenoid (3rd)...................................................................................................1632 [DXH6KB] Ground Fault of ECMV Solenoid (3rd)....................................................................................................1634 [DXH6KY] Hot Short of ECMV Solenoid (3rd).......................................................................................................1636 [DXH7KA] Disconnection of ECMV Solenoid (Reverse)...............................................................................................1638 [DXH7KB] Ground Fault of ECMV Solenoid (Reverse)................................................................................................1640 [DXH7KY] Hot Short of ECMV Solenoid (Reverse)...................................................................................................1642 [DXH8KA] Disconnection of ECMV Solenoid (Forward)...............................................................................................1644 [DXH8KB] Ground Fault of ECMV Solenoid (Forward)................................................................................................1646 [DXH8KY] Hot Short of ECMV Solenoid (Forward)...................................................................................................1648 [DXHHKA] Disconnection of ECMV Solenoid (4th)...................................................................................................1650 [DXHHKB] Ground Fault of ECMV Solenoid (4th)....................................................................................................1652 [DXHHKY] Hot Short of ECMV Solenoid (4th).......................................................................................................1654 [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT)................................................................................................1656 [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT).................................................................................................1658 [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT)....................................................................................................1660 [DXHKKA] Disconnection of 3rd EPC Solenoid (RET)................................................................................................1662 [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET).................................................................................................1664 [DXHKKY] Hot Short of 3rd EPC Solenoid (RET)....................................................................................................1666 [DXJEKA] Disconnection of 4th EPC Solenoid (EXT)................................................................................................1668 [DXJEKB] Ground Fault of 4th EPC Solenoid (EXT).................................................................................................1670 [DXJEKY] Hot Short of 4th EPC Solenoid (EXT)....................................................................................................1672 [DXJFKA] Disconnection of 4th EPC Solenoid (RET)................................................................................................1674 [DXJFKB] Ground Fault of 4th EPC Solenoid (RET).................................................................................................1676 [DXJFKY] Hot Short of 4th EPC Solenoid (RET)....................................................................................................1678 [DY30MA] Malfunction 1 of Emerg. Steering Motor.................................................................................................1680 [DY30MC] Malfunction 2 of Emerg. Steering Motor.................................................................................................1684 [DY30ME] Emergency Steering Long-Time Activated.................................................................................................1688 [H2K0KA] Failure of Quick Coupler Lock Signal...................................................................................................1692 [H2K0KY] Hot Short of Quick Coupler Lock Signal.................................................................................................1695 [LA00L3] Failure of Fan Reverse.................................................................................................................1698 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).......................................................................................................1700 E-1 Engine Does Not Start.......................................................................................................................1700 E-2 Manual Preheating System Does Not Work......................................................................................................1708 E-3 Automatic Preheating System Does Not Work...................................................................................................1712 E-4 While Preheating is Working, Preheating Monitor Does Not Light Up...........................................................................1714 E-5 All of LCD Unit, LED Unit, and Meter Unit on Machine Monitor Display Nothing................................................................1716 E-6 LCD Unit on Machine Monitor Displays Nothing................................................................................................1720 E-7 Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Out or Flickers).......................................................1722 E-8 LCD on Machine Monitor Does Not Display Properly............................................................................................1724 E-9 Meter Unit Display on Machine Monitor is Abnormal...........................................................................................1726 E-10 Night Lighting Lamp of Meter Unit on Machine Monitor is Abnormal...........................................................................1730 E-11 Caution LED on Machine Monitor is Abnormal.................................................................................................1734 E-12 LED of Switch Panel on Machine Monitor is Abnormal or Switches Does Not Operate Properly...................................................1738 E-13 Two Switches Operation of Switch Panel on Machine Monitor Does Not Function................................................................1742 E-14 Switch Panel Buzzer of Machine Monitor is Abnormal.........................................................................................1746 E-15 Rear View Monitor Does Not Light Up or Backlight Flickers..................................................................................1750 E-16 Rear View Monitor Images are not Displayed Clearly.........................................................................................1754 E-17 Rear View Monitor Brightness cannot be Adjusted............................................................................................1758 E-18 Night Lighting Lamp of Rear View Monitor is Abnormal.......................................................................................1762 E-19 Some Items of Gauges and Caution Lamps on Machine Monitor are not Displayed Properly.......................................................1765 E-20 Parking Brake Indicator Lamp does not Light When the Parking Brake is Set to ON (Parking) Position.........................................1766 E-21 When Brake Accumulator Oil Pressure Drops, the Brake Oil Pressure Caution Lamp does not Light..............................................1770 Front Brake.................................................................................................................................1770 Rear Brake..................................................................................................................................1772 E-22 Air Cleaner Clogging Indicator Lamp does not Light.........................................................................................1774 E-23 Radiator Coolant Level Caution Lamp does not Light.........................................................................................1776 E-24 Indication of Hydraulic Oil Temperature Gauge does not Increase, or Hydraulic Oil Temperature Caution Lamp does not Light..................1778 E-25 Indication of Torque Converter Oil Temperature Gauge does not Increase, or Torque Converter Oil Temperature Caution Lamp does not Light....1779 E-26 Fuel Level Gauge does not Indicate Correct Level...........................................................................................1780 E-27 Seat Belt Caution Lamp Indication is Abnormal..............................................................................................1782 E-28 Horn does not Sound........................................................................................................................1784 E-29 Horn does not Stop Sounding................................................................................................................1788 E-30 Alarm Buzzer does not Sound................................................................................................................1790 E-31 When Starting Switch is in ON Position, Alarm Buzzer does not Stop Sounding................................................................1792 E-32 Kick-Down does not Work when kick-Down Switch is Turned ON.................................................................................1794 E-33 The Hold Switch does not Work When it is Pressed...........................................................................................1796 E-34 Parking Brake does not Work Even if it is Applied, or the Brake Drags When Parking Brake is Released and FR Drive is Operated..............1798 E-35 Transmission Cut-Off Mode is not Selected or not Released..................................................................................1802 E-36 Transmission Cut-Off Setting cannot be Released............................................................................................1804 E-37 Directional Selector (FNR) Switch Mode is not Selected or not Released.....................................................................1806 E-38 When Operating Engine Power Selection Switch, Engine Power Selection Function does not Operate Properly....................................1808 E-39 Flow of Loader Pump does not Increase from the Minimum Rate................................................................................1810 E-40 ECSS Function cannot be Selected or cannot be Released.....................................................................................1812 E-41 None of Headlamp, Clearance Lamp, and Tail Lamp Light......................................................................................1814 E-42 Clearance Lamp and Tail Lamp do not Light Up or go Out.....................................................................................1816 E-43 Both "High and Low Beams" of Headlamp do not Light Up or Go Out............................................................................1820 E-44 The Headlamp "Low Beam" does not Light Up or Go Out........................................................................................1824 E-45 The Headlamp "High Beam" does not Light Up or Go Out.......................................................................................1826 E-46 Front Working Lamp does not Light Up or Go Out.............................................................................................1828 E-47 Rear Working Lamp does not Light Up or Go Out..............................................................................................1832 E-48 All of Turn Signal Lamps and Hazard Lamps do not Light Up or Go Out........................................................................1836 E-49 Turn Signal Lamps do not Light Up or Go Out................................................................................................1840 E-50 Hazard Lamp does not Light Up or Go Out....................................................................................................1844 E-51 Brake Lamp does not Light Up or Stays Lighted..............................................................................................1848 E-52 Back-Up Lamp does not Light or Continues To Light..........................................................................................1852 E-53 Back-Up Buzzer does not Sound or Continues to Sound........................................................................................1856 E-54 Front Wiper does not Operate...............................................................................................................1858 E-55 Rear Wiper does not Operate................................................................................................................1862 E-56 Window Washer does not Operate.............................................................................................................1866 E-57 KOMTRAX System does not Operate Properly...................................................................................................1870 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE).........................................................................................1872 Information Mentioned in Troubleshooting Table (H-mode).........................................................................................1872 System Chart of Hydraulic and Mechanical Systems................................................................................................1873 Failure Mode and Cause Table....................................................................................................................1876 H-1 Machine Does Not Start......................................................................................................................1886 H-2 Torque Converter Lockup is Not Disengaged (Engine Stalls)...................................................................................1890 H-3 Torque Converter Lockup Clutch is Not Engaged...............................................................................................1890 H-4 Travel Speed is Slow, Bucket Thrusting Force is Weak, Gradability is Low, or Gear Speed Does Not Shift......................................1891 H-5 Large Shock is Made When Machine Starts or Gear is Shifted..................................................................................1894 H-6 Machine Starts or Gear Speed Shifts with Long Time Lag......................................................................................1898 H-7 Torque Converter Oil Temperature is High....................................................................................................1902 H-8 Machine Does Not Turn.......................................................................................................................1906 H-9 Turning Response is Poor....................................................................................................................1908 H-10 Steering Wheel is Heavy to Turn............................................................................................................1910 H-11 Machine Sways or Large Shocks Are Made While Machine Turns.................................................................................1912 H-12 Turning Radius Differs Between Right and Left Turns........................................................................................1914 H-13 Wheel Brakes Do Not Work or Are Weak.......................................................................................................1916 H-14 Wheel Brakes Are Not Released or Drag......................................................................................................1918 H-15 Parking Brake Does Not Work or It is Weak..................................................................................................1918 H-16 Parking Brake is Not Released or It Drags (Including Emergency Release System).............................................................1919 H-17 Boom Does Not Rise.........................................................................................................................1920 H-18 Boom Moves Slow or Boom Lacks Lifting Force................................................................................................1922 H-19 Rising Boom Slows Down at Certain Height...................................................................................................1924 H-20 Boom Cylinders Do Not Serve to Hold Bucket on Ground.......................................................................................1925 H-21 Hydraulic Drift of Boom is Large...........................................................................................................1926 H-22 Boom Moves Up and Down During Operation....................................................................................................1927 H-23 Bucket Does Not Tilt Back..................................................................................................................1928 H-24 Bucket Moves Slow or Bucket Lacks Tilt-Back Force..........................................................................................1930 H-25 Bucket Decelerates During Tilt-Back Operation..............................................................................................1932 H-26 Bucket Cylinder Does Not Hold Bucket on Ground.............................................................................................1934 H-27 Hydraulic Drift of Bucket is Large.........................................................................................................1935 H-28 Bucket Tilts Back and Forth During Carrying Load (Work Equipment Valve in “Hold”)..........................................................1936 H-29 Boom and Bucket Control Levers Do Not Move Smoothly and Heavy to Move......................................................................1937 H-30 Operating Work Equipment Causes Engine Speed to Lower Significantly or Engine to Stall.....................................................1938 H-31 Large Shocks Are Made When Work Equipment Starts to Move and Stops.........................................................................1940 H-32 When Certain Work Equipment Stalls Hydraulically, Other Work Equipment Moves...............................................................1941 H-33 E.C.S.S. (Travel Damper) Does Not Work and Machine Pitches and Bounces.....................................................................1942 H-34 Air Conditioner Does Not Work While Cooling Fan Rotates in Reverse Mode....................................................................1943 H-35 Fan Speed is Abnormal (Too High or Low, or Fan Does Not Rotate)............................................................................1944 H-36 Unusual Noise is Heard from Around Fan.....................................................................................................1945 TROUBLESHOOTING OF ENGINE (S-MODE)..................................................................................................................1946 Information Mentioned in Troubleshooting Table (S-Mode).........................................................................................1946 S-1 When Starting Switch is Turned to START Position, Engine Does Not Crank.....................................................................1947 S-2 When Engine Cranks, but No Exhaust Smoke Comes Out..........................................................................................1948 S-3 Fuel is Being Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)..............................................1949 S-4 Engine Startability is Poor.................................................................................................................1951 S-5 Engine Does Not Pick Up Smoothly............................................................................................................1953 S-6 Engine Stops During Operation...............................................................................................................1955 S-7 Engine Runs Rough or is Unstable............................................................................................................1957 S-8 Engine Lacks Power..........................................................................................................................1958 S-9 Exhaust Smoke is Black (KDPF Clogs Up Early)................................................................................................1961 S-10 Engine Oil Consumption is Excessive........................................................................................................1963 S-11 Oil Becomes Contaminated Quickly...........................................................................................................1964 S-12 Fuel Consumption is Excessive..............................................................................................................1965 S-13 Oil is in Coolant (or Coolant Spurts or Coolant Level Goes Down)...........................................................................1966 S-14 Engine Oil Pressure Drops..................................................................................................................1967 S-15 Fuel Mixes in Engine Oil...................................................................................................................1969 S-16 Water mixes into Engine Oil (Milky)........................................................................................................1970 S-17 Coolant Temperature Rises Too High (Overheating)...........................................................................................1971 S-18 Unusual Noise is Heard.....................................................................................................................1972 S-19 Vibration is Excessive.....................................................................................................................1973 S-20 Air Cannot Be Bled From Circuit............................................................................................................1974 S-21 Active Regeneration is Executed Frequently.................................................................................................1975 S-22 Active Regeneration Takes Time.............................................................................................................1976 S-23 White Smoke is Exhausted During Active Regeneration........................................................................................1977 50 DISASSEMBLY AND ASSEMBLY.............................................................................................................................1979 HOW TO READ THIS SECTION............................................................................................................................1984 Removal and Installation of Assemblies..........................................................................................................1984 Special Tools...............................................................................................................................1984 Removal.....................................................................................................................................1984 Installation................................................................................................................................1984 Disassembly and Assembly of Assemblies..........................................................................................................1985 Special Tools...............................................................................................................................1985 Disassembly.................................................................................................................................1985 Assembly....................................................................................................................................1985 COATING MATERIALS LIST..............................................................................................................................1986 SPECIAL TOOLS LIST..................................................................................................................................1990 SKETCHES OF SPECIAL TOOLS...........................................................................................................................1994 CONNECTOR REPAIR PROCEDURES.........................................................................................................................2002 Stripping Insulation............................................................................................................................2002 Wire Inspection.................................................................................................................................2002 Contact Terminal Removal (HD30 Type)............................................................................................................2003 Crimping Contact Terminal (HD30 Type)...........................................................................................................2004 Insertion Of Contact Terminal (HD30 Type).......................................................................................................2005 Contact Terminal Removal (DT Type)..............................................................................................................2006 Crimping Contact Terminal (DT Type).............................................................................................................2007 Insertion Of Contact Terminal (DT Type).........................................................................................................2008 ENGINE AND COOLING SYSTEM...........................................................................................................................2009 Supply Pump Assembly............................................................................................................................2009 Removal.....................................................................................................................................2009 Installation................................................................................................................................2012 Injector Assembly...............................................................................................................................2014 Special Tools...................................................................................................................................2014 Removal.....................................................................................................................................2014 Installation................................................................................................................................2021 Cylinder Head Assembly..........................................................................................................................2028 Removal.....................................................................................................................................2028 Installation................................................................................................................................2038 Engine Hood.....................................................................................................................................2054 Removal.....................................................................................................................................2054 Installation................................................................................................................................2057 Grille Assembly.................................................................................................................................2058 Removal.....................................................................................................................................2058 Installation................................................................................................................................2059 Cooling System Assembly.........................................................................................................................2060 Removal.....................................................................................................................................2060 Installation................................................................................................................................2062 Radiator Core Assembly..........................................................................................................................2064 Removal.....................................................................................................................................2064 Installation................................................................................................................................2067 After Cooler....................................................................................................................................2068 Removal.....................................................................................................................................2068 Installation................................................................................................................................2069 Hydraulic Oil Cooler............................................................................................................................2070 Removal.....................................................................................................................................2070 Installation................................................................................................................................2070 Fuel Cooler Assembly............................................................................................................................2071 Removal.....................................................................................................................................2071 Installation................................................................................................................................2071 Engine, Torque Converter and Transmission Assemblies............................................................................................2072 Removal.....................................................................................................................................2072 Installation................................................................................................................................2080 Disconnect and Connection of Engine, Torque Converter and Transmission Assembly.................................................................2084 Disconnection...............................................................................................................................2084 Connection..................................................................................................................................2085 Engine Front Oil Seal...........................................................................................................................2086 Removal.....................................................................................................................................2086 Installation................................................................................................................................2088 Engine Rear Oil Seal............................................................................................................................2090 Removal.....................................................................................................................................2090 Installation................................................................................................................................2091 Cooling Fan and Fan Motor Assembly..............................................................................................................2094 Removal.....................................................................................................................................2094 Installation................................................................................................................................2095 KDPF Assembly...................................................................................................................................2096 Removal.....................................................................................................................................2096 Installation................................................................................................................................2099 Disassembly and Assembly of KDPF Assembly.......................................................................................................2100 Disassembly.................................................................................................................................2100 Assembly....................................................................................................................................2106 KCCV Assembly...................................................................................................................................2112 Removal.....................................................................................................................................2112 Installation................................................................................................................................2112 Air Cleaner Assembly............................................................................................................................2114 Removal.....................................................................................................................................2114 Installation................................................................................................................................2116 Fuel Tank.......................................................................................................................................2118 Removal.....................................................................................................................................2118 Installation................................................................................................................................2121 POWER TRAIN.........................................................................................................................................2122 Disassembly and Assembly of Torque Converter Assembly...........................................................................................2122 Disassembly.................................................................................................................................2122 Assembly....................................................................................................................................2125 Transmission....................................................................................................................................2132 Disassembly.................................................................................................................................2132 Assembly....................................................................................................................................2139 Transmission Clutch Pack Assembly...............................................................................................................2150 Disassembly.................................................................................................................................2150 Assembly....................................................................................................................................2158 Differential Assembly...........................................................................................................................2171 Disassembly.................................................................................................................................2171 Assembly....................................................................................................................................2180 Parking Brake...................................................................................................................................2196 Disassembly.................................................................................................................................2196 Assembly....................................................................................................................................2199 Front Axle......................................................................................................................................2206 Removal.....................................................................................................................................2206 Installation................................................................................................................................2207 Rear Axle.......................................................................................................................................2208 Removal.....................................................................................................................................2208 Installation................................................................................................................................2210 Axle Housing....................................................................................................................................2213 Disassembly.................................................................................................................................2213 Assembly....................................................................................................................................2218 STEERING SYSTEM.....................................................................................................................................2226 Steering Valve Assembly.........................................................................................................................2226 Removal.....................................................................................................................................2226 Installation................................................................................................................................2227 BRAKE SYSTEM........................................................................................................................................2228 Parking Brake Discs and Plates..................................................................................................................2228 Removal.....................................................................................................................................2228 Drain the oil from the transmission case....................................................................................................2228 Installation................................................................................................................................2230 UNDERCARRAGE AND FRAME..............................................................................................................................2232 Center Hinge Pin................................................................................................................................2232 Installation................................................................................................................................2237 Counterweight...................................................................................................................................2242 Removal.....................................................................................................................................2242 Installation................................................................................................................................2243 Full-Length Fender Assembly.....................................................................................................................2244 Removal.....................................................................................................................................2244 Installation................................................................................................................................2245 HYDRAULIC SYSTEM....................................................................................................................................2246 Hydraulic Tank Assembly.........................................................................................................................2246 Removal.....................................................................................................................................2246 Installation................................................................................................................................2249 Work Equipment Control Valve....................................................................................................................2250 Removal.....................................................................................................................................2250 Installation................................................................................................................................2254 Power Train Pump and Work Equipment Pump Assembly...............................................................................................2256 Removal.....................................................................................................................................2256 Installation................................................................................................................................2257 Steering Pump And Cooling Fan Pump Assembly.....................................................................................................2258 Installation................................................................................................................................2259 Hydraulic Cylinder..............................................................................................................................2260 Disassembly.................................................................................................................................2260 Assembly....................................................................................................................................2264 WORK EQUIPMENT......................................................................................................................................2270 Work Equipment Assembly.........................................................................................................................2270 Removal.....................................................................................................................................2270 Installation................................................................................................................................2274 CAB AND ATTACHMENTS.................................................................................................................................2278 Cab and Floor Frame.............................................................................................................................2278 Removal.....................................................................................................................................2278 Installation................................................................................................................................2282 Cab Glass (Stuck Window Glass)..................................................................................................................2284 Removal.....................................................................................................................................2284 Installation................................................................................................................................2285 Operator Seat Assembly..........................................................................................................................2293 Removal.....................................................................................................................................2293 Installation................................................................................................................................2294 Seat Belt.......................................................................................................................................2295 Removal.....................................................................................................................................2295 Installation................................................................................................................................2295 ELECTRICAL SYSTEM...................................................................................................................................2296 Machine Monitor Assembly........................................................................................................................2296 Removal.....................................................................................................................................2296 Installation................................................................................................................................2296 Engine Controller Assembly......................................................................................................................2297 Removal.....................................................................................................................................2297 Installation................................................................................................................................2297 Work Equipment Controller Assembly..............................................................................................................2299 Removal.....................................................................................................................................2299 Installation................................................................................................................................2300 Transmission Controller Assembly................................................................................................................2301 Removal.....................................................................................................................................2301 Installation................................................................................................................................2301 Monitor Controller Assembly.....................................................................................................................2302 Removal.....................................................................................................................................2302 Installation................................................................................................................................2304 Mass Air Flow and Temperature Sensor............................................................................................................2306 Removal.....................................................................................................................................2306 Installation................................................................................................................................2306 KOMTRAX Terminal Assembly.......................................................................................................................2307 Removal.....................................................................................................................................2307 Installation................................................................................................................................2307 60 MAINTENANCE STANDARD.................................................................................................................................2309 ENGINE AND COOLING SYSTEM...........................................................................................................................2312 Engine Related Parts............................................................................................................................2312 Cooling Fan Clamp...............................................................................................................................2314 Servo Valve.....................................................................................................................................2316 Cooling Fan Motor...............................................................................................................................2318 POWER TRAIN.........................................................................................................................................2320 Drive Shaft.....................................................................................................................................2320 Torque Converter................................................................................................................................2321 Transmission....................................................................................................................................2324 Forward and Reverse Clutches....................................................................................................................2330 1st and 4th Clutches............................................................................................................................2331 2nd and 3rd Clutches............................................................................................................................2332 Transmission Control Valve......................................................................................................................2334 Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV......................................................................................2336 Lockup Clutch ECMV..............................................................................................................................2337 Main Relief and Torque Converter Relief Valve...................................................................................................2338 Differential....................................................................................................................................2340 Front Differential (Standard: Conventional Differential)....................................................................................2340 Rear differential (Standard: Conventional Differential).....................................................................................2342 Limited Slip Differential.......................................................................................................................2344 Front Axle..................................................................................................................................2344 Rear Axle...................................................................................................................................2346 Final Drive.....................................................................................................................................2348 STEERING SYSTEM.....................................................................................................................................2350 Steering Column.................................................................................................................................2350 Steering Pump...................................................................................................................................2351 Pump Body.......................................................................................................................................2352 Servo Valve.....................................................................................................................................2354 Steering Valve..................................................................................................................................2355 Steering Cylinder...............................................................................................................................2356 Emergency Steering Pump (if equipped)...........................................................................................................2358 Brake System....................................................................................................................................2360 Charge Valve................................................................................................................................2360 Brakes..........................................................................................................................................2362 Front Brake.................................................................................................................................2362 Rear Brake..................................................................................................................................2363 Parking Brake...............................................................................................................................2364 Parking Brake Solenoid Valve................................................................................................................2365 UNDERCARRIAGE AND FRAME.............................................................................................................................2366 Axle Mount and Center Hinge Pin.................................................................................................................2366 HYDRAULIC SYSTEM....................................................................................................................................2370 Hydraulic Tank..................................................................................................................................2370 Double Type Gear Pump...........................................................................................................................2371 Power Train Charge Pump and Power Train Lubrication Pump....................................................................................2371 WORK EQUIPMENT PUMP.................................................................................................................................2373 Pump Body.......................................................................................................................................2374 Servo Valve.....................................................................................................................................2376 CONTROL VALVE.......................................................................................................................................2378 STABILIZER VALVE....................................................................................................................................2390 WORK EQUIPMENT......................................................................................................................................2392 Work Equipment Linkage..........................................................................................................................2392 BUCKET..............................................................................................................................................2394 WORK EQUIPMENT CYLINDER.............................................................................................................................2396 Boom Cylinder...................................................................................................................................2396 Bucket Cylinder.................................................................................................................................2396 80 AIR CONDITIONING.....................................................................................................................................2397 AIR CONDITIONER.....................................................................................................................................2400 Precautions for Refrigerant.....................................................................................................................2400 Air Conditioner Component.......................................................................................................................2402 Structure and Function of Refrigeration System..................................................................................................2404 Overview of Refrigeration System................................................................................................................2405 Air Conditioner Unit............................................................................................................................2408 Function....................................................................................................................................2409 Functions of Major Components...................................................................................................................2411 Evaporator..................................................................................................................................2411 Heater Core.................................................................................................................................2411 Evaporator Temperature Sensor...............................................................................................................2411 Inner Sensor................................................................................................................................2411 Blower Amplifier............................................................................................................................2411 Blower Off Relay............................................................................................................................2411 Compressor Clutch Relay.....................................................................................................................2411 Servomotor..................................................................................................................................2412 Expansion Valve.............................................................................................................................2413 Dual Pressure Switch........................................................................................................................2413 Air Conditioner Controller..................................................................................................................2413 Compressor..................................................................................................................................2414 Condenser...................................................................................................................................2415 Receiver....................................................................................................................................2416 Sunlight Sensor.............................................................................................................................2417 Outside Air Temperature Sensor..................................................................................................................2417 Inspection and Troubleshooting Procedure of Air Conditioner.....................................................................................2417 Basic Inspection and Troubleshooting Sequence...............................................................................................2418 Air Conditioner Circuit Diagram and Arrangement of Connector Pins...............................................................................2420 System Diagram..................................................................................................................................2422 Parts and Connectors Layout.....................................................................................................................2424 Testing with Self-Diagnosis Function............................................................................................................2429 How to Enter Air Conditioner “Electrical Systems” Screen in Service Mode of the Machine Monitor.................................................2430 Testing Temperature Control System..............................................................................................................2432 Testing.....................................................................................................................................2432 Testing Vent (Mode) Changeover..................................................................................................................2434 Testing.....................................................................................................................................2434 Testing FRESH/RECIRC Air Changeover.............................................................................................................2436 Testing Relay...................................................................................................................................2437 Troubleshooting Chart 1.........................................................................................................................2438 Troubleshooting Chart 2.........................................................................................................................2439 Information Mentioned in Troubleshooting Table..................................................................................................2442 Information in Troubleshooting Table........................................................................................................2442 Troubleshooting with Gauge Pressure.............................................................................................................2444 Testing Refrigerant Pressure....................................................................................................................2448 Precautions for Disconnecting and Connecting Refrigerant Piping.................................................................................2450 Disconnection...............................................................................................................................2450 Connection..................................................................................................................................2450 Filling Compressor Oil..........................................................................................................................2452 90 DIAGRAMS AND SCHEMATICS..............................................................................................................................2455 HYDRAULIC SYSTEM....................................................................................................................................2457 Hydraulic Circuit Diagram.......................................................................................................................2460 Power Train Hydraulic Circuit Diagram...........................................................................................................2461 ELECTRICAL SYSTEM...................................................................................................................................2463 Symbols in Electrical Circuit Diagram...........................................................................................................2463 Electrical Circuit Diagram (1/5)................................................................................................................2467 Electrical Circuit Diagram (2/5)................................................................................................................2468 Electrical Circuit Diagram (3/5)................................................................................................................2469 Electrical Circuit Diagram (4/5)................................................................................................................2470 Electrical Circuit Diagram (5/5)................................................................................................................2471 Electrical Circuit Floor Diagram (1/8)..........................................................................................................2472 Electrical Circuit Floor Diagram (2/8)..........................................................................................................2473 Electrical Circuit Floor Diagram (3/8)..........................................................................................................2474 Electrical Circuit Floor Diagram (4/8)..........................................................................................................2475 Electrical Circuit Floor Diagram (5/8)..........................................................................................................2476 Electrical Circuit Floor Diagram (6/8)..........................................................................................................2477 Electrical Circuit Floor Diagram (7/8)..........................................................................................................2478 Electrical Circuit Floor Diagram (8/8)..........................................................................................................2479 Electrical Circuit Air Conditioner Diagram......................................................................................................2480
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