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Komatsu WA430-5 Wheel Loader Shop Manual 60001 and up – PDF DOWNLOAD
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Komatsu WA430-5 Wheel Loader Shop Manual 60001 and up
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WA430-5 60001 and up
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Description
Komatsu WA430-5 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA430-5 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA430-5
Serial Number: 60001 and up
Book Code: SEBM025405
Language: English
Pages: 1166
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA430-5 Wheel Loader Shop Manual
FOREWORD:
GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu WA430-5 Wheel Loader Shop Manual
COVER......................................................................................................................................................................................................... 1 CONTENTS...................................................................................................................................................................................................... 2 01 GENERAL.................................................................................................................................................................................................... 28 GENERAL ASSEMBLY DRAWING.................................................................................................................................................................................. 29 SPECIFICATIONS............................................................................................................................................................................................ 30 WEIGHT TABLE.............................................................................................................................................................................................. 34 LIST OF LUBRICANT AND COOLANT............................................................................................................................................................................. 36 10 STRUCTURE AND FUNCTION,MAINTENANCE STANDARD................................................................................................................................................................ 38 COOLING SYSTEM............................................................................................................................................................................................ 39 ENGINE MOUNT, TRANSMISSION MOUNT.......................................................................................................................................................................... 40 POWER TRAIN............................................................................................................................................................................................... 41 POWER TRAIN SYSTEM DIAGRAM................................................................................................................................................................................ 42 DRIVE SHAFT (PROPELLER SHAFT)............................................................................................................................................................................. 45 TORQUE CONVERTER,TRANSMISSION PIPING...................................................................................................................................................................... 46 TORQUE CONVERTER.......................................................................................................................................................................................... 47 TRANSMISSION.............................................................................................................................................................................................. 55 TRANSMISSION CONTROL VALVE................................................................................................................................................................................ 70 AXLE...................................................................................................................................................................................................... 85 DIFFERENTIAL.............................................................................................................................................................................................. 87 FINAL DRIVE............................................................................................................................................................................................... 98 AXLE MOUNTING,CENTER HINGE PIN............................................................................................................................................................................ 103 STEERING PIPING........................................................................................................................................................................................... 107 STEERING COLUMN,ORBIT-ROLL................................................................................................................................................................................ 108 STEERING VALVE............................................................................................................................................................................................ 109 ORBIT-ROLL VALVE.......................................................................................................................................................................................... 124 STOP VALVE................................................................................................................................................................................................ 128 STEERING PUMP, SWITCH PUMP................................................................................................................................................................................ 129 EMERGENCY STEERING PUMP(OP)............................................................................................................................................................................... 131 EMERGENCY STEERING MOTOR(OP).............................................................................................................................................................................. 132 STEERING CYLINDER......................................................................................................................................................................................... 133 JOYSTICK STEERING LEVER (OP).............................................................................................................................................................................. 135 STEERING LEVER (OP)....................................................................................................................................................................................... 136 STEERING SWITCH VALVE (OP)................................................................................................................................................................................ 138 BRAKE PIPING.............................................................................................................................................................................................. 139 BRAKE VALVE............................................................................................................................................................................................... 141 CHARGE VALVE.............................................................................................................................................................................................. 148 ACCUMULATOR (FOR BRAKE)................................................................................................................................................................................... 152 BRAKE..................................................................................................................................................................................................... 154 PARKING BRAKE CONTROL..................................................................................................................................................................................... 159 PARKING BRAKE............................................................................................................................................................................................. 160 PARKING BRAKE SOLENOID VALVE.............................................................................................................................................................................. 162 PARKING BRAKE EMERGENCY RELEASE VALVE..................................................................................................................................................................... 164 HYDRAULIC PIPING.......................................................................................................................................................................................... 165 WORK EQUIPMENT CONTROL LEVER.............................................................................................................................................................................. 168 HYDRAULIC TANK............................................................................................................................................................................................ 170 TORQUE CONVERTER CHARGING,WORK EQUIPMENT,AND PILOT CONTROL PUMPS.......................................................................................................................................... 172 PPC RELIEF VALVE.......................................................................................................................................................................................... 174 E.S.S.S .VALVE (OP)....................................................................................................................................................................................... 176 WORK EQUIPMENT CONTROL VALVE.............................................................................................................................................................................. 178 WORK EQUIPMENT PPC VALVE.................................................................................................................................................................................. 195 PPC VALVE (FOR MULTI FUNCTION MONO LEVER)................................................................................................................................................................. 201 OPERATION................................................................................................................................................................................................. 203 EPC SOLENOID VALVE(OP).................................................................................................................................................................................... 207 SHUT OFF VALVE (OP)....................................................................................................................................................................................... 210 ATTACHMENT PPC VALVE(OP).................................................................................................................................................................................. 211 COOLING FAN MOTOR......................................................................................................................................................................................... 215 COOLING FAN MOTOR DRIVE PUMP.............................................................................................................................................................................. 220 WORK EQUIPMENT LINKAGE.................................................................................................................................................................................... 228 BUCKET.................................................................................................................................................................................................... 230 BUCKET POSITIONER,LIFT ARM KICK-OUT....................................................................................................................................................................... 231 WORK EQUIPMENT CYLINDER................................................................................................................................................................................... 237 CAB....................................................................................................................................................................................................... 238 AIR CONDITIONER (OP)...................................................................................................................................................................................... 239 MACHINE MONITORING SYSTEM................................................................................................................................................................................. 240 MACHINE MONITOR........................................................................................................................................................................................... 247 TRANSMISSION CONTROL SYSTEM............................................................................................................................................................................... 313 TRANSMISSION CONTROLLER................................................................................................................................................................................... 341 WORK EQUIPMENT CONTROL SYSTEM (OP)........................................................................................................................................................................ 343 WORK EQUIPMENT CONTROLLER................................................................................................................................................................................. 358 ELECTRIC TRANSMISSION CONTROL............................................................................................................................................................................. 360 KICK DOWN,HOLD SWITCH..................................................................................................................................................................................... 364 ENGINE STARTING CIRCUIT................................................................................................................................................................................... 365 ENGINE STOP CIRCUIT....................................................................................................................................................................................... 367 PREHEATING CIRCUIT........................................................................................................................................................................................ 368 ENGINE POWER MODE SELECTOR CIRCUIT ....................................................................................................................................................................... 369 PARKING BRAKE CIRCUIT..................................................................................................................................................................................... 370 SENSORS................................................................................................................................................................................................... 374 20 TESTING AND ADJUSTING...................................................................................................................................................................................... 384 TESTING AND ADJUSTING DATA................................................................................................................................................................................ 385 STANDARD VALUE TABLE FOR CHASSIS.......................................................................................................................................................................... 386 TESTING AND ADJUSTING..................................................................................................................................................................................... 393 TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING....................................................................................................................................................... 394 MEASURING ENGINE SPEED................................................................................................................................................................................ 395 MEASURING EXHAUST COLOR............................................................................................................................................................................... 397 MEASURING EXHAUST TEMPERATURE......................................................................................................................................................................... 398 ADJUSTING VALVE CLEARANCE............................................................................................................................................................................. 400 MEASURING COMPRESSION PRESSURE........................................................................................................................................................................ 401 MEASURING BLOW-BY PRESSURE............................................................................................................................................................................ 402 MEASURING ENGINE OIL PRESSURE......................................................................................................................................................................... 403 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)........................................................................................................................................................ 404 TESTING AND ADJUSTING FUEL INJECTION TIMING........................................................................................................................................................... 405 ADJUSTING ENGINE SPEED SENSOR......................................................................................................................................................................... 407 BLEEDING AIR FROM FUEL CIRCUIT........................................................................................................................................................................ 408 ADJUSTING ENGINE STOP MOTOR LEVER..................................................................................................................................................................... 409 ADJUSTING ACCELERATOR PEDAL .......................................................................................................................................................................... 411 ADJUSTING TRANSMISSION SPEED SENSOR................................................................................................................................................................... 413 TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE........................................................................................................................................................ 414 DRAWING OF SPECIAL TOOL............................................................................................................................................................................... 418 PROCEDURE FOR FLUSHING TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT................................................................................................................................ 419 PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS............................................................................................................................................ 420 TESTING AND ADJUSTING STEERING CONTROL................................................................................................................................................................ 422 TESTING AND ADJUSTING STEERING OIL PRESSURE........................................................................................................................................................... 423 TESTING HYDRAULIC FAN................................................................................................................................................................................. 425 MEASURING BRAKE OIL PRESSURE.......................................................................................................................................................................... 426 TESTING WEAR OF WHEEL BRAKE DISC...................................................................................................................................................................... 428 BLEEDING AIR FROM BRAKE CIRCUIT....................................................................................................................................................................... 429 TESTING WEAR OF PARKING BRAKE DISC.................................................................................................................................................................... 430 MANUAL RELEASE METHOD FOR PARKING BRAKE............................................................................................................................................................... 431 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE..................................................................................................................................................... 432 TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE.............................................................................................................................................. 434 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE............................................................................................................................................... 436 TESTING AND ADJUSTING BUCKET POSITIONER............................................................................................................................................................... 438 TESTING AND ADJUSTING LIFT ARM KICK-OUT............................................................................................................................................................... 439 CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP........................................................................................................................................................ 440 ADJUSTING MACHINE MONITOR............................................................................................................................................................................. 441 TESTING AND ADJUSTING LOAD METER...................................................................................................................................................................... 444 BLEEDING AIR.......................................................................................................................................................................................... 448 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT..................................................................................................................................................... 449 RELEASING REMAINING PRESSURE IN TRAVEL DAMPER CIRCUIT................................................................................................................................................. 449 PM CLINIC INSPECTION CHART............................................................................................................................................................................ 450 TROUBLESHOOTING........................................................................................................................................................................................... 452 POINTS TO REMEMBER WHEN TROUBLESHOOTING............................................................................................................................................................... 453 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................................................................................. 454 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE............................................................................................................................................................. 455 CHECKS BEFORE TROUBLESHOOTING......................................................................................................................................................................... 463 SPECIAL FUNCTIONS OF MACHINE MONITOR.................................................................................................................................................................. 464 CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................................................................... 497 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS............................................................................................................................................................ 505 T-ADAPTER TABLE....................................................................................................................................................................................... 527 CONNECTOR TYPES AND MOUNTING LOCATIONS................................................................................................................................................................ 530 CONNECTOR LAYOUT DRAWING.............................................................................................................................................................................. 538 TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM(TM MODE)............................................................................................................................................... 546 TRANSMISSION CONTROL SYSTEM DIAGRAM............................................................................................................................................................... 549 ERROR CODE [1500L1] (DOUBLE ENGAGEMENT DETECTED) IS DISPLAYED..................................................................................................................................... 552 ERROR CODE [15SAL1] (F_ECMV (E-POCV) FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED............................................................................................................. 553 ERROR CODE [15SALH] (F_ECMV (E-POCV) FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED................................................................................................................ 554 ERROR CODE [15SBL1] (R_ECMV (E-POCV) FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED............................................................................................................. 555 ERROR CODE [15SBLH] (R_ECMV (E-POCV) FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED................................................................................................................ 556 ERROR CODE [15SEL1] (1ST_ECMV (E-POCV) FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED........................................................................................................... 557 ERROR CODE [15SELH] (1ST_ECMV (E-POCV) FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED.............................................................................................................. 558 ERROR CODE [15SFL1] (2ND_ECMV (E-POCV) FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED........................................................................................................... 559 ERROR CODE [15SFLH] (2ND_ECMV (E-POCV) FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED.............................................................................................................. 560 ERROR CODE [15SGL1] (3RD_ECMV (E-POCV) FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED........................................................................................................... 561 ERROR CODE [15SGLH] (3RD_ECMV (E-POCV) FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED.............................................................................................................. 562 ERROR CODE [15SHL1] (4TH_ECMV (E-POCV) FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED........................................................................................................... 563 ERROR CODE [15SHLH] (4TH_ECMV (E-POCV) FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED.............................................................................................................. 564 ERROR CODE [15SJL1] (LOCKUP_ECMV (E-POCV) FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED........................................................................................................ 565 ERROR CODE [15SJLH] (LOCKUP_ECMV (E-POCV) FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED........................................................................................................... 566 ERROR CODE [989F00] (TRANSMISSION PROTECTION CAUTION) IS DISPLAYED................................................................................................................................ 567 ERROR CODE [B@C7NS] (REAR BRAKE COOLING OIL OVERHEAT) IS DISPLAYED................................................................................................................................ 568 ERROR CODE [D150KA] (EMERGENCY STEERING RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED............................................................................................................ 569 ERROR CODE [D150KB] (EMERGENCY STEERING RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED................................................................................................................ 570 ERROR CODE [D160KA] (BACKUP LAMP RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED................................................................................................................... 571 ERROR CODE [D160KB] (BACKUP LAMP RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED....................................................................................................................... 572 ERROR CODE [D191KA] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED................................................................................................................ 573 ERROR CODE [D191KB] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED.................................................................................................................... 575 ERROR CODE [D192KA] (TRAVEL DAMPER RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED................................................................................................................. 577 ERROR CODE [D192KB] (TRAVEL DAMPER RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED..................................................................................................................... 578 ERROR CODE [D198KB] (GROUND FAULT IN LOW TEMPERATURE BYPASS RELAY SYSTEM) IS DISPLAYED [*]........................................................................................................ 579 ERROR CODE [D198KY] (HOT-SHORT IN LOW-TEMPERATURE BYPASS RELAY SYSTEM) IS DISPLAYED............................................................................................................... 580 ERROR CODE [DAQ0KK] (CONTROLLER POWER SUPPLY VOLTAGE LOWERED) IS DISPLAYED........................................................................................................................ 581 ERROR CODE [DAQ2KK] (DEFECTIVE SOLENOID POWER SUPPLY SYSTEM) IS DISPLAYED......................................................................................................................... 582 ERROR CODE [DAQ9KQ] (MODEL SELECTION SIGNAL MISMATCH) IS DISPLAYED................................................................................................................................ 583 ERROR CODE [DDK3KA] (RIGHT FNR SWITCH SIGNAL NOT INPUT) IS DISPLAYED.............................................................................................................................. 584 ERROR CODE [DDK3KB] (MULTIPLE RIGHT FNR SWITCH SIGNAL INPUT) IS DISPLAYED......................................................................................................................... 586 ERROR CODE [DDK4KA] (JOYSTICK FORWARD/REVERSE SWITCH SIGNAL IS NOT INPUT) IS DISPLAYED............................................................................................................ 588 ERROR CODE [DDK4KB] (MULTIPLE JOYSTICK FORWARD/REVERSE SWITCH SIGNALS ARE INPUT) IS DISPLAYED..................................................................................................... 590 ERROR CODE [DDK5LD] (SHORT CIRCUIT WITH POWER SOURCE IN JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH) IS DISPLAYED......................................................................................... 592 ERROR CODE [DDK6KA] (FORWARD-REVERSE LEVER SIGNAL NOT INPUT) IS DISPLAYED......................................................................................................................... 593 ERROR CODE [DDK6KB] (MULTIPLE FORWARD-REVERSE LEVER SIGNAL INPUT) IS DISPLAYED.................................................................................................................... 595 ERROR CODE [DDS5KA] (STEERING PRESSURE SWITCH DISCONNECTED) IS DISPLAYED.......................................................................................................................... 597 ERROR CODE [DDS5KB] (STEERING PRESSURE SWITCH GROUNDED) IS DISPLAYED.............................................................................................................................. 598 ERROR CODE [DDT0L4] (MANUAL/AUTO-SHIFT SELECTOR SWITCH SELECTION FAILURE) IS DISPLAYED............................................................................................................ 599 ERROR CODE [DDT4LD] (GROUND FAULT OF TRANSMISSION CUT-OFF SETTING SWITCH) IS DISPLAYED............................................................................................................ 601 ERROR CODE [DDW9LD] (GROUND FAULT OF KICKDOWN SWITCH SYSTEM) IS DISPLAYED......................................................................................................................... 602 ERROR CODE [DDWLLD] (GROUND FAULT OF HOLD SWITCH SYSTEM) IS DISPLAYED............................................................................................................................. 604 ERROR CODE [DF10KA] (NO INPUT OF GEAR SHIFT LEVER SIGNAL) IS DISPLAYED............................................................................................................................ 606 ERROR CODE [DF10KB] (INPUT OF MULTIPLE GEAR SHIFT LEVER SIGNALS NO INPUT OF GEAR SHIFT LEVER SIGNAL) IS DISPLAYED................................................................................. 608 ERROR CODE [DGF1KX] (TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM FAILURE) IS DISPLAYED............................................................................................................. 610 ERROR CODE [DGR2KA] (REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM DISCONNECTION) IS DISPLAYED......................................................................................................... 611 ERROR CODE [DGR2KB] (GROUND FAULT OF REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED....................................................................................................... 612 ERROR CODE [DHT1KX] (TRANSMISSION CUT-OFF (LEFT BRAKE PRESSURE SENSOR) SIGNAL DISCONTINUITY) IS DISPLAYED......................................................................................... 613 ERROR CODE [DLE2KA] (ENGINE REVOLUTION SENSOR SYSTEM DISCONTINUITY) IS DISPLAYED.................................................................................................................. 614 ERROR CODE [DLE2LC] (ENGINE REVOLUTION SENSOR FAILURE) IS DISPLAYED............................................................................................................................... 615 ERROR CODE [DLT3KA] (SPEED SENSOR TRANSMISSION OUTPUT SHAFT REVOLUTION SYSTEM DISCONTINUITY) IS DISPLAYED......................................................................................... 616 ERROR CODE [DT20KB] (GROUND FAULT OF BUILT-IN INDICATOR LAMP SYSTEM OF TRANSMISSION CUT-OFF SWITCH) IS DISPLAYED.................................................................................. 617 ERROR CODE [DW7BKA] (FAN PUMP REVERSE SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED................................................................................................................. 618 ERROR CODE [DW7BKB] (FAN PUMP REVERSE SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED.............................................................................................................. 619 ERROR CODE [DW7CKA] (SWITCH PUMP CUT-OFF RELAY DISCONTINUITY) IS DISPLAYED........................................................................................................................ 620 ERROR CODE [DW7CKB] (SWITCH PUMP CUT-OFF RELAY GROUND FAULT) IS DISPLAYED......................................................................................................................... 621 ERROR CODE [DX16KA] (FAN PUMP EPC SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED..................................................................................................................... 622 ERROR CODE [DX16KB] (FAN PUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...................................................................................................................... 623 ERROR CODE [DXH1KA] (LOCK-UP CLUTCH_ECMV (E-POCV) SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED..................................................................................................... 624 ERROR CODE [DXH1KB] (LOCK-UP CLUTCH_ECMV (E-POCV) SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED.................................................................................................. 625 ERROR CODE [DXH4KA] (1ST_ECMV (E-POCV) SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED................................................................................................................ 626 ERROR CODE [DXH4KB] (1ST_ECMV (E-POCV) SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED............................................................................................................. 627 ERROR CODE [DXH5KA] (2ND_ECMV (E-POCV) SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED................................................................................................................ 628 ERROR CODE [DXH5KB] (2ND_ECMV (E-POCV) SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED............................................................................................................. 629 ERROR CODE [DXH6KA] (3RD_ECMV (E-POCV) SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED................................................................................................................ 630 ERROR CODE [DXH6KB] (3RD_ECMV (E-POCV) SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED............................................................................................................. 631 ERROR CODE [DXH7KA] (R_ECMV (E-POCV) SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED.................................................................................................................. 632 ERROR CODE [DXH7KB] (R_ECMV (E-POCV) SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED................................................................................................................... 633 ERROR CODE [DXH8KA] (F_ECMV (E-POCV) SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED.................................................................................................................. 634 ERROR CODE [DXH8KB] (F_ECMV (E-POCV) SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED................................................................................................................... 635 ERROR CODE [DXHHKA] (4TH_ECMV (E-POCV) SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED................................................................................................................ 636 ERROR CODE [DXHHKB] (4TH_ECMV (E-POCV) SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED............................................................................................................. 637 ERROR CODE [DY30MA] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE))................................................................................................... 638 ERROR CODE [DY30MC] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE))................................................................................................... 640 TROUBLESHOOTING CODE[TM-1] DISCONTINUITY OR HOT SHORT-CIRCUITING OF KICKDOWN SWITCH SYSTEM........................................................................................................ 642 TROUBLESHOOTING CODE[TM-2] HOLD SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING............................................................................................................... 644 TROUBLESHOOTING CODE[TM-3] TORQUE CONVERTER LOCK-UP SWITCH SYSTEM FAILURE......................................................................................................................... 646 TROUBLESHOOTING CODE[TM-4] NEUTRALIZER SIGNAL (PARKING BRAKE SWITCH SIGNAL) SYSTEM FAILURE........................................................................................................ 647 TROUBLESHOOTING CODE[TM-5] EMERGENCY STEERING SWITCH (MOTOR-DRIVEN EMERGENCY STEERING OPERATION SWITCH) SIGNAL SYSTEM FAILURE..................................................................... 649 TROUBLESHOOTING CODE[TM-6] TRANSMISSION CUT-OFF SWITCH SYSTEM DISCONTINUITY OR GROUND FAULT....................................................................................................... 651 TROUBLESHOOTING CODE[TM-7] TRANSMISSION CUT-OFF SETTING SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING....................................................................................... 652 TROUBLESHOOTING CODE[TM-8] TRANSMISSION CUT-OFF (LEFT BRAKE SENSOR) SIGNAL SHORT-CIRCUITING....................................................................................................... 653 TROUBLESHOOTING CODE[TM-9a] JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH SYSTEM FAILURE (DISCONTINUITY OR GROUND FAULT).................................................................................... 654 TROUBLESHOOTING CODE[TM-9b] JOYSTICK ON/OFF CHANGE OVER SWITCH SYSTEM FAILURE..................................................................................................................... 655 TROUBLESHOOTING CODE[TM-10] FNR SWITCH MODE CHANGE OVER SWITCH SYSTEM FAILURE..................................................................................................................... 657 TROUBLESHOOTING CODE[TM-11] "STARTING SWITCH""C""(IGN_C) SIGNAL SYSTEM FAILURE.................................................................................................................... 658 TROUBLESHOOTING CODE[TM-12] ENGINE POWER MODE SWITCH DISCONTINUITY OR GROUND FAULT................................................................................................................ 660 TROUBLESHOOTING CODE[TM-13] THE ENGINE POWER MODE CANNOT BE SELECTED.............................................................................................................................. 661 TROUBLESHOOTING CODE[TM-14] TRAVEL DAMPER NO/OFF SWITCH DISCONTINUITY OR GROUND FAULT [*]......................................................................................................... 663 TROUBLESHOOTING CODE[TM-15] HYDRAULIC FAN REVERSE SWITCH SIGNAL SYSTEM HOT SHORT-CIRCUITING OR DISCONTINUITY...................................................................................... 664 TROUBLESHOOTING CODE[TM-16] MOTOR-DRIVEN EMERGENCY STEERING RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING.............................................................................................. 665 TROUBLESHOOTING CODE[TM-17] TRAVEL DAMPER RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING [*]............................................................................................................ 666 TROUBLESHOOTING CODE[TM-18] SWITCH PUMP CUT-OFF RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING.......................................................................................................... 667 TROUBLESHOOTING CODE[TM-19] BACK LAMP RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING.................................................................................................................... 668 TROUBLESHOOTING CODE[TM-20] NEUTRAL OUTPUT SYSTEM HOT SHORT-CIRCUITING............................................................................................................................ 669 TROUBLESHOOTING CODE[TM-21] FECMV (E-POCV) SOLENOID SYSTEM HOT SHORT-CIRCUITING................................................................................................................... 670 TROUBLESHOOTING CODE[TM-22] RECMV (E-POCV) SOLENOID SYSTEM HOT SHORT-CIRCUITING................................................................................................................... 671 TROUBLESHOOTING CODE[TM-23] 1ST ECMV (E-POCV) SOLENOID SYSTEM HOT SHORT-CIRCUITING................................................................................................................ 672 TROUBLESHOOTING CODE[TM-24] 2ND ECMV (E-POCV) SOLENOID SYSTEM HOT SHORT-CIRCUITING................................................................................................................ 673 TROUBLESHOOTING CODE[TM-25] 3RD ECMV (E-POCV) SOLENOID SYSTEM HOT SHORT-CIRCUITING................................................................................................................ 674 TROUBLESHOOTING CODE[TM-26] 4TH ECMV (E-POCV) SOLENOID SYSTEM HOT SHORT-CIRCUITING................................................................................................................ 675 TROUBLESHOOTING CODE[TM-27] LOCK-UP ECMV (E-POCV) SOLENOID SYSTEM HOT SHORT-CIRCUITING............................................................................................................ 676 TROUBLESHOOTING CODE[TM-28] FAN PUMP EPC SOLENOID SYSTEM HOT SHORT-CIRCUITING..................................................................................................................... 677 TROUBLESHOOTING CODE[TM-29] FAN REVERSE SOLENOID SYSTEM HOT SHORT-CIRCUITING...................................................................................................................... 678 TROUBLESHOOTING CODE[TM-30] SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM FAILURE.................................................................................................... 679 TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM(WRK MODE)............................................................................................................................................ 680 WORK EQUIPMENT CONTROL SYSTEM DIAGRAM............................................................................................................................................................. 683 ERROR CODE [D193KA] (DEFECTIVE JOYSTICK STEERING CUT RELAY SYSTEM (MAIN SYSTEM DISCONNECTED)) IS DISPLAYED........................................................................................ 686 ERROR CODE [D193KB] (THE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM IS GROUNDED PROPERLY) IS DISPLAYED............................................................................................. 687 ERROR CODE [DB90KK] (LOWERING WORK EQUIPMENT CONTROLLER POWER SUPPLY) IS DISPLAYED................................................................................................................ 688 ERROR CODE [DB92KK] (DEFECTIVE SOLENOID ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED................................................................................................................ 689 ERROR CODE [DB95KX] (DEFECTIVE 5V ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED...................................................................................................................... 690 ERROR CODE [DD1ALD] (DEFECTIVE REMOTE POSITIONER UP SET SWITCH (GROUND FAULT)) IS DISPLAYED....................................................................................................... 692 ERROR CODE [DD1BLD] (DEFECTIVE REMOTE POSITIONER DOWN SET SWITCH (GROUND FAULT)) IS DISPLAYED..................................................................................................... 693 ERROR CODE [DFA0KM] (DEFECTIVE NEUTRAL CAUTION FOR JOYSTICK WORK EQUIPMENT LEVER) IS DISPLAYED.................................................................................................... 694 ERROR CODE [DK59KA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED................................................................. 695 ERROR CODE [DK59KY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORT CIRCUIT)) IS DISPLAYED......................................................................................... 696 ERROR CODE [DK59L8] (DEFECTIVE LIFT ARM EPC POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED............................................................................. 697 ERROR CODE [DK5AKA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OF MAIN) (DISCONNECTION, GROUND OF SUB)) IS DISPLAYED....................................................... 698 ERROR CODE [DK5AKY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED.......................................................................................... 699 ERROR CODE [DK5BKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED................................................................... 700 ERROR CODE [DK5BKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORTED)) IS DISPLAYED................................................................................................. 701 ERROR CODE [DK5BL8] (DEFECTIVE INPUT SIGNAL FOR BUCKET EPC LEVER POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED........................................................ 702 ERROR CODE [DK5CKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED.................................................................... 703 ERROR CODE [DK5CKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED............................................................................................ 704 ERROR CODE [DK5DKA] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED.................................................................... 705 ERROR CODE [DK5DKY] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORT CIRCUIT)) IS DISPLAYED.................................................................................... 706 ERROR CODE [DK5DL8] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED......................................................... 707 ERROR CODE [DK5EKA] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED................................................................. 708 ERROR CODE [DK5EKY] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED......................................................................................... 709 ERROR CODE [DK5FKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED........................................................ 710 ERROR CODE [DK5FKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORTED)) IS DISPLAYED.............................................................................. 711 ERROR CODE [DK5FKM] (JOYSTICK STEERING EPC LEVER NEUTRAL SYSTEM CAUTION) IS DISPLAYED............................................................................................................. 712 ERROR CODE [DK5FL8] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DEVIATION OF POSITIONAL SIGNALS OF MAIN AND SUB-CIRCUITS)) IS DISPLAYED............................. 713 ERROR CODE [DG5GKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUND FAULT OF SUB-CIRCUIT)) IS DISPLAYED...................................................... 714 ERROR CODE [DK5GKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT SHORT CIRCUIT)) IS DISPLAYED......................................................................... 715 ERROR CODE [DKA0KA] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (DISCONNECTION OR GROUND FAULT)) IS DISPLAYED......................................................................................... 716 ERROR CODE [DKA0KY] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (SHORT CIRCUIT)) IS DISPLAYED......................................................................................................... 717 ERROR CODE [DLE2LC] (DEFECTIVE ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED........................................................................................................................... 718 ERROR CODE [DLT3LC] (DEFECTIVE TRANSMISSION OUTPUT AXIS SPEED SENSOR SYSTEM (DISCONNECTED)) IS DISPLAYED.......................................................................................... 719 ERROR CODE [DUM1KB] (REMOTE POSITIONER RAISE LAMP SYSTEM GROUND FAULT) IS DISPLAYED............................................................................................................... 720 ERROR CODE [DUM2KB] (REMOTE POSITIONER LOWER LAMP SYSTEM GROUND FAULT) IS DISPLAYED............................................................................................................... 721 ERROR CODE [DW4PKA] (DISCONNECTED LIFT ARM RAISE EPC SOLENOID SYSTEM) IS DISPLAYED................................................................................................................ 722 ERROR CODE [DW4PKB] (LIFT ARM RAISE EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED................................................................................................................ 723 ERROR CODE [DW4QKA] (DISCONNECTED LIFT ARM LOWER EPC SOLENOID SYSTEM) IS DISPLAYED................................................................................................................ 724 ERROR CODE [DW4QKB] (LIFT ARM LOWER EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED................................................................................................................ 725 ERROR CODE [DW4RKA] (DISCONNECTED BUCKET TILT EPC SOLENOID SYSTEM) IS DISPLAYED................................................................................................................... 726 ERROR CODE [DW4RKB] (BUCKET TILT EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED................................................................................................................... 727 ERROR CODE [DW4SKA] (BUCKET DUMP EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED.................................................................................................................. 728 ERROR CODE [DW4SKB] (BUCKET DUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED................................................................................................................... 729 ERROR CODE [DWM1KA] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED...................................................................................................... 730 ERROR CODE [DWM1KB] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED....................................................................................................... 731 ERROR CODE [DWN6KA] (LIFT ARM RAISE MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED.............................................................................................................. 732 ERROR CODE [DWN6KB] (LIFT ARM RAISE MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED............................................................................................................... 733 ERROR CODE [DWN7KA] (LIFT ARM FLOATING MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED........................................................................................................... 734 ERROR CODE [DWN7KB] (LIFT ARM FLOATING MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED............................................................................................................ 735 ERROR CODE [DWN8KA] (BUCKET TILT MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED................................................................................................................. 736 ERROR CODE [DWN8KB] (BUCKET TILT MAGNET DETENT SYSTEM FAILURE (POWER SUPPLY SYSTEM GROUND FAULT)) IS DISPLAYED.................................................................................... 737 ERROR CODE [DXHJKA] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED.......................................................................................................... 738 ERROR CODE [DXHJKB] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED........................................................................................................... 739 ERROR CODE [DXHKKA] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED......................................................................................................... 740 ERROR CODE [DXHKKB] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED.......................................................................................................... 741 ERROR CODE [DXHLKA] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED................................................................................................. 742 ERROR CODE [DXHLKB] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED.................................................................................................. 743 ERROR CODE [DXHMKA] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED.................................................................................................. 744 ERROR CODE [DXHMKB] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED................................................................................................... 745 TROUBLESHOOTING CODE [WRK-1] DEFECTIVE LIFT ARM LOCK SWITCH SYSTEM................................................................................................................................ 746 TROUBLESHOOTING CODE [WRK-2] DEFECTIVE REMOTE POSITIONER RAISE SETTING SWITCH SYSTEM.............................................................................................................. 747 TROUBLESHOOTING CODE [WRK-3] DEFECTIVE REMOTE POSITIONER LOWER SETTING SWITCH SYSTEM.............................................................................................................. 748 TROUBLESHOOTING CODE [WRK-4] DEFECTIVE REMOTE POSITIONER RAISE SELECTION SWITCH SYSTEM............................................................................................................ 750 TROUBLESHOOTING CODE [WRK-5] DEFECTIVE REMOTE POSITIONER LOWER ON/OFF SETTING SWITCH SYSTEM....................................................................................................... 752 TROUBLESHOOTING CODE [WRK-6] DEFECTIVE BUCKET CYLINDER PROXIMITY SWITCH SYSTEM.................................................................................................................... 754 TROUBLESHOOTING CODE [WRK-7] DEFECTIVE BUCKET CYLINDER FULL STROKE DETECTION SWITCH SYSTEM........................................................................................................ 756 TROUBLESHOOTING CODE [WRK-8] DEFECTIVE SEMI-AUTOMATIC DIGGING HARD SELECTION SWITCH SYSTEM........................................................................................................ 757 TROUBLESHOOTING CODE [WRK-9] DEFECTIVE SEMI-AUTOMATIC DIGGING SOFT SELECTION SWITCH SYSTEM........................................................................................................ 758 TROUBLESHOOTING CODE [WRK-10] DEFECTIVE JOYSTICK ON/OFF SWITCH SYSTEM............................................................................................................................. 759 TROUBLESHOOTING CODE [WRK-11] DEFECTIVE JOYSTICK STEERING SPEED HI/LO SWITCH SYSTEM............................................................................................................... 761 TROUBLESHOOTING CODE [WRK-12] DEFECTIVE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM................................................................................................................. 762 TROUBLESHOOTING CODE [WRK-13] HOT SHORT-CIRCUITED LIFT ARM RAISE MAGNET DETENT OUTPUT SYSTEM...................................................................................................... 763 TROUBLESHOOTING CODE [WRK-14] HOT SHORT-CIRCUITED LIFT ARM FLOATING MAGNET DETENT OUTPUT SYSTEM................................................................................................... 764 TROUBLESHOOTING CODE [WRK-15] HOT SHORT-CIRCUITED BUCKET TILT MAGNET DETENT OUTPUT SYSTEM......................................................................................................... 765 TROUBLESHOOTING CODE [WRK-16] HOT SHORT-CIRCUITED WORK EQUIPMENT NEUTRAL LOCK SOLENOID OUTPUT SYSTEM.............................................................................................. 766 TROUBLESHOOTING CODE [WRK-17] HOT SHORT-CIRCUITED LIFT ARM RAISE EPC SOLENOID SYSTEM.............................................................................................................. 767 TROUBLESHOOTING CODE [WRK-18] HOT SHORT-CIRCUITED LIFT ARM LOWER EPC SOLENOID SYSTEM.............................................................................................................. 768 TROUBLESHOOTING CODE [WRK-19] HOT SHORT-CIRCUITED BUCKET TILT EPC SOLENOID SYSTEM................................................................................................................. 769 TROUBLESHOOTING CODE [WRK-20] HOT SHORT-CIRCUITED BUCKET DUMP EPC SOLENOID SYSTEM................................................................................................................. 770 TROUBLESHOOTING CODE [WRK-21] HOT SHORT-CIRCUITED 3 VALVES EXTENSION EPC SOLENOID SYSTEM.......................................................................................................... 771 TROUBLESHOOTING CODE [WRK-22] HOT SHORT-CIRCUITED 3 VALVES RETRACTION EPC SOLENOID SYSTEM......................................................................................................... 772 TROUBLESHOOTING CODE [WRK-23] HOT SHORT-CIRCUITED JOYSTICK STEERING RIGHT EPC SOLENOID SYSTEM..................................................................................................... 773 TROUBLESHOOTING CODE [WRK-24] HOT SHORT-CIRCUITED JOYSTICK STEERING LEFT EPC SOLENOID SYSTEM...................................................................................................... 774 TROUBLESHOOTING CODE [WRK-25] DEFECTIVE BUCKET POSITIONER,LIFT ARM KICK-OUT AND FLOATING HOLDING FUNCTION......................................................................................... 775 TROUBLESHOOTING CODE [WRK-26] DEFECTIVE LIFT ARM KICK-OUT FUNCTION AND CANCELLATION............................................................................................................... 777 TROUBLESHOOTING CODE [WRK-27] DEFECTIVE BUCKET LEVELER FUNCTION AND CANCELLATION.................................................................................................................. 779 TROUBLESHOOTING CODE [WRK-28] DEFECTIVE LIFT ARM FLOATING HOLDING AND CANCELLATION................................................................................................................ 781 TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE).......................................................................................................................................................... 783 MONITOR SYSTEM DIAGRAM............................................................................................................................................................................ 785 ERROR CODE [2F00MA] DRAGGING OF PARKING BRAKE..................................................................................................................................................... 789 ERROR CODE [2G42ZG] ACCUMULATOR OIL PRESSURE (FRONT CIRCUIT) LOW.................................................................................................................................. 791 ERROR CODE [2G43ZG] ACCUMULATOR OIL PRESSURE (REAR BRAKE CIRCUIT) LOW............................................................................................................................. 792 ERROR CODE [AA1ANX] AIR CLEANER 1 CLOGGED......................................................................................................................................................... 793 ERROR CODE [AB00L6] DEFECTIVE BATTERY CHARGING CIRCUIT (ALTERNATOR TERMINAL R SIGNAL DETECTED WHEN ENGINE STOPPED................................................................................. 795 ERROR CODE [AB00MA] DEFECTIVE BATTERY CHARGING CIRCUIT (NO ALTERNATOR TERMINAL R SIGNAL DETECTED,DETECTION FAILURE)............................................................................... 796 ERROR CODE [B@BAZG] ENGINE OIL PRESSURE LOW....................................................................................................................................................... 797 ERROR CODE [B@BAZK] ENGINE OIL LEVEL LOW.......................................................................................................................................................... 798 ERROR CODE [B@BCNS] ENGINE WATER TEMPERATURE OVERHEATING.......................................................................................................................................... 799 ERROR CODE [B@BCZK] ALARM INDICATING LOW COOLANT LEVEL............................................................................................................................................ 800 ERROR CODE [B@HANS] HYDRAULIC OIL TEMPERATURE OVERHEATING......................................................................................................................................... 801 ERROR CODE [B@CENS] TORQUE CONVERTER OIL TEMPERATURE OVERHEATING.................................................................................................................................. 802 ERROR CODE [D182KZ] THE PREHEATER RELAY COIL IS DISCONNECTED OR SHIRT-CIRCUITED................................................................................................................... 803 ERROR CODE [D5ZHL6] STARTING SWITCH C (IGN""C"") INPUT FAILURE.................................................................................................................................... 805 ERROR CODE [DA80L4] AUTO GREASE INPUT FAILURE..................................................................................................................................................... 806 ERROR CODE [DAF3KK] SW POWER SUPPLY (FOR OPERATION) = ON AND NSW POWER SUPPLY (FOR MEMORY) IS OFF................................................................................................. 807 ERROR CODE [DAF5KP] 5V POWER SUPPLY OUTPUT FAILURE................................................................................................................................................ 809 ERROR CODE [DAF6KP] 24V POWER SUPPLY OUTPUT FAILURE............................................................................................................................................... 810 ERROR CODE [DAFBKM] WRONG INFORMATION ON MODEL SELECTION.......................................................................................................................................... 812 ERROR CODE [DAFSKQ] WRONG INFORMATION ON METER DISPLAY SELECTION.................................................................................................................................. 813 ERROR CODE [DAQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND TRANSMISSION CONTROLLER) .............................................................................................. 814 ERROR CODE [DbQsKr] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) ............................................................................................ 815 ERROR CODE [DB9SKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) ............................................................................................ 816 ERROR CODE [DD15LD] MONITOR PANEL MODE SELECTOR SWITCH 1 [■] (PANEL SW1) INPUT ERROR.............................................................................................................. 817 ERROR CODE [DD16LD] MONITOR PANEL MODE SELECTOR SWITCH 1 [◇] (PANEL SW2) INPUT ERROR.............................................................................................................. 818 ERROR CODE [DD17LD] THE MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SW3) INPUT CIRCUIT REMAINS CLOSED FOR MORE THAN ONE MINUTE................................................................ 819 ERROR CODE [DD18LD] MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SW4) INPUT ERROR.............................................................................................................. 820 ERROR CODE [DD1CLD] SUB-TOTAL SWITCH FAILURE [*].................................................................................................................................................. 821 ERROR CODE [DDS5L6] DECREASED STEERING OIL PRESSURE............................................................................................................................................... 823 ERROR CODE [DDY0LD] CANCEL SWITCH FAILURE [*]..................................................................................................................................................... 825 ERROR CODE [DGE2KX] ENGINE WATER TEMPERATURE SENSOR SYSTEM FAILURE................................................................................................................................ 827 ERROR CODE [dge3L6] ABNORMAL CONNECTION OF ENGINE WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM............................................................................................... 828 ERROR CODE [DGH2KX] HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM FAILURE............................................................................................................................... 829 ERROR CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM FAILURE........................................................................................................................ 830 ERROR CODE [DHE4L6] ENGINE OIL PRESSURE SENSOR SYSTEM FAILURE..................................................................................................................................... 831 ERROR CODE [DHPCKX] BOTTOM PRESSURE SENSOR FAILURE [*]............................................................................................................................................ 832 ERROR CODE [DHPDKX] HEAD PRESSURE SENSOR FAILURE [*].............................................................................................................................................. 834 ERROR CODE [DKA0KX] LIFT ARM ANGLE SENSOR FAILURE [*]............................................................................................................................................. 836 ERROR CODE [DV00KB] SHORT-CIRCUITED ALARM BUZZER OUTPUT SYSTEM.................................................................................................................................... 837 ERROR CODE [DY30ME] THE EMERGENCY STEERING REMAINS ACTUATED FOR MORE THAN ONE MINUTE.............................................................................................................. 838 TROUBLESHOOTING CODE [MON-1] THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT UP WHEN THE PARKING BRAKE SWITCH IS TURNED ON (THE PARKING BRAKE INDICATOR SWITCH CIRCUIT SUFFERS A GROUND FAULT).... 840 TROUBLESHOOTING CODE [MON-2] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (FRONT CIRCUIT)............................................................ 842 TROUBLESHOOTING CODE [MON-3] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (REAR CIRCUIT)............................................................. 843 TROUBLESHOOTING CODE [MON-4] THE AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT ON............................................................................................................ 844 TROUBLESHOOTING CODE [MON-5] THE ENGINE HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON.................................................................................................................. 846 TROUBLESHOOTING CODE [MON-6] THE ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT ON.................................................................................................................. 847 TROUBLESHOOTING CODE [MON-7] THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON.......................................................................................................... 848 TROUBLESHOOTING CODE [MON-8] THE RADIATOR WATER VOLUME CAUTION LAMP DOES NOT LIGHT ON............................................................................................................. 849 TROUBLESHOOTING CODE [MON-9] THE HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON......................................................................................................... 850 TROUBLESHOOTING CODE [MON-10] THE TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON................................................................................................. 851 TROUBLESHOOTING CODE [MON-11] THE STEERING HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON............................................................................................................... 852 TROUBLESHOOTING CODE [MON-12] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 [■] (PANEL SW1).......................................................................................................... 853 TROUBLESHOOTING CODE [MON-13] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 [◇] (PANEL SW2).......................................................................................................... 854 TROUBLESHOOTING CODE [MON-14] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 [<] (PANEL SW3).......................................................................................................... 855 TROUBLESHOOTING CODE [MON-15] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 [>] (PANEL SW4).......................................................................................................... 856 TROUBLESHOOTING CODE [MON-16] DEFECTIVE SUBTOTAL SWITCH........................................................................................................................................... 857 TROUBLESHOOTING CODE [MON-17] DEFECTIVE CANCEL SWITCH............................................................................................................................................. 858 TROUBLESHOOTING CODE [MON-18] DEFECTIVE BOTTOM PRESSURE SENSOR (HOT SHORT FAULT).................................................................................................................. 859 TROUBLESHOOTING CODE [MON-19] DEFECTIVE HEAD SENSOR............................................................................................................................................... 860 TROUBLESHOOTING CODE [MON-20] THE ALARM BUZZER DOES NOT SOUND OR STOP (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN BUZZER OUTPUT SYSTEM)................................................ 861 TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)............................................................................................................................................... 862 H-1 THE MACHINE DOES NOT START.................................................................................................................................................................... 863 H-2 THE LOCK-UP CLUTCH IS NOT RELEASED (THE ENGINE STOPS)(WHEN THE LOCK-UP CLUTCH IS PROVIDED).................................................................................................... 865 H-3a THE TRAVED SPEED IS SLOW,THE THRUSTING FORCE IS WEAK,THE UPHILL TRAVELING POWER IS WEAK,AND THE GEAR IS NOT SHIFTED.......................................................................... 866 H-3b THE TORQUE CONVERTER LOCK-UP CLUTCH IS NOT LOT IN(IF THE LOCK-UP CLUTCH IS EQUIPPED)......................................................................................................... 868 H-4 SHOCKS ARE LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR................................................................................................................................... 869 H-5 TIME LAG IS LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR.................................................................................................................................. 871 H-6 THE TORQUE CONVERTER OIL TEMPERATURE IS HIGH.................................................................................................................................................. 873 H-7 THE STEERING WHEEL DOES NOT TURN.............................................................................................................................................................. 874 H-8 THE STEERING WHEEL IS HEAVY................................................................................................................................................................... 875 H-9 THE STEERING WHEEL FLUCTUATES OR IS STRONGLY SHOCKED.......................................................................................................................................... 876 H-10 THE MACHINE STEERS TO ONE SIDE WHEN TRAVELING................................................................................................................................................ 876 H-11 THE RIGHT AND LEFT SWING RADII ARE DIFFERENT................................................................................................................................................. 876 H-12 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL................................................................................................................................................ 877 H-13 THE BRAKE IS NOT RELEASED OR IS DRAGGED...................................................................................................................................................... 878 H-14 THE BRAKE IS NOT RELEASED OR DRAGGED......................................................................................................................................................... 879 H-15 THE LIFT ARM DOES NOT RISE................................................................................................................................................................... 880 H-16 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT....................................................................................................................... 881 H-17 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT............................................................................................................................. 882 H-18 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET(THE BUCKER RISES IN THE AIR)............................................................................................................... 882 H-19 HYDRAULIC DRIFTS OF THE LIFE ARM OCCUR OFTEN................................................................................................................................................. 882 H-20 THE LIFT ARM WOBBLES DURING OPERATION........................................................................................................................................................ 882 H-21 WHEN THE CONTROL LOVER IS SWITCHED FROM "HOLD" TO "RAISE," THE LIFT ARM FALLS TEMPORARILY.................................................................................................... 883 H-22 THE BUCKET DOES NOT TILT BACK................................................................................................................................................................ 884 H-23 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT............................................................................................................................ 885 H-24 THE BUCKET COMES TO OPERATE SLOWLY IN THE MIDST OF TILTING-BACK.............................................................................................................................. 886 H-25 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET.............................................................................................................................................. 886 H-26 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN................................................................................................................................................... 886 H-27 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO "HOLD")...................................................................................................... 887 H-28 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "TILT," THE BUCKET FALLS TEMPORARILY....................................................................................................... 887 H-29 THE CONTROL LEVERS OF LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY..................................................................................................................... 888 H-30 ECSS DOES NOT WORK,AND THERE IS PITCHING AND BOUNCING........................................................................................................................................ 889 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)......................................................................................................................................................... 890 ELECTRICAL SYSTEM DIAGRAM......................................................................................................................................................................... 891 TROUBLESHOOTING CODE:[E-1-a] (THE ENGINE DOES NOT START. (STARTING SYSTEM))....................................................................................................................... 892 TROUBLESHOOTING CODE:[E-1-b] (THE ENGINE DOES NOT START).......................................................................................................................................... 896 TROUBLESHOOTING CODE:[E-2] (THE ENGINE DOES NOT STOP)............................................................................................................................................. 898 TROUBLESHOOTING CODE:[E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT)................................................................................................................................. 900 TROUBLESHOOTING CODE:[E-4] (THE ENGINE POWER MODES CANNOT BE SELECTED)............................................................................................................................ 902 TROUBLESHOOTING CODE:[E-5] (THE FRONT WIPER DOES NOT FUNCTION).................................................................................................................................... 904 TROUBLESHOOTING CODE:[E-6] (THE REAR WIPER DOES NOT FUNCTION)..................................................................................................................................... 907 TROUBLESHOOTING CODE:[E-7] (THE SIDE WIPER DOES NOT FUNCTION (IF EQUIPPED))....................................................................................................................... 909 TROUBLESHOOTING CODE:[E-8] (THE WIND WASHER DOES NOT FUNCTION).................................................................................................................................... 910 TROUBLESHOOTING CODE:[E-9] (THE HEADLAMP (LO BEAM) DOES NOT LIGHT ON)............................................................................................................................. 913 TROUBLESHOOTING CODE:[E-10] (THE HEADLAMP (HI BEAM) DOES NOT FUNCTION)............................................................................................................................ 916 TROUBLESHOOTING CODE:[E-11] (THE CLEARANCE LAMP DOES NOT LIGHT ON (SMALL LAMP))................................................................................................................... 918 TROUBLESHOOTING CODE:[E-12] (THE TURN SIGNAL DOES NOT BLINK)...................................................................................................................................... 919 TROUBLESHOOTING CODE:[E-13] (THE BORN DOES NOT SOUND)............................................................................................................................................. 921 TROUBLESHOOTING CODE:[E-14] (THE AIR CONDITIONER DOES NOT WORK OR DOES NOT STOP).................................................................................................................. 923 TROUBLESHOOTING OF ENGINE (S MODE).................................................................................................................................................................... 926 METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................................................................................ 927 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)..................................................................................................................................... 931 S-2 ENGINE DOES NOT START......................................................................................................................................................................... 932 (1) ENGINE DOES NOT TURN...................................................................................................................................................................... 932 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED).................................................................................................................. 933 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)................................................................................................................ 934 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).......................................................................................................................................... 935 S-4 ENGINE STOPS DURING OPERATIONS................................................................................................................................................................ 936 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)..................................................................................................................................................... 937 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER).......................................................................................................................................................... 938 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)................................................................................................................................................ 939 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)....................................................................................................................................... 940 S-9 OIL BECOMES CONTAMINATED QUICKLY.............................................................................................................................................................. 941 S-10 FUEL CONSUMPTION IS EXCESSIVE................................................................................................................................................................ 942 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN........................................................................................................................ 943 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)................................................................................................................................... 944 S-13 OIL LEVEL RISES (WATER,FUEL IN OIL).......................................................................................................................................................... 945 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)............................................................................................................................................. 946 S-15 ABNORMAL NOISE IS MADE....................................................................................................................................................................... 947 S-16 VIBRATION IS EXCESSIVE....................................................................................................................................................................... 948 30 DISASSEMBLY AND ASSEMBLY................................................................................................................................................................................... 949 HOW TO READ THIS MANUAL................................................................................................................................................................................... 951 PRECAUTIONS WHEN PERFORMING OPERATION..................................................................................................................................................................... 953 SPECIAL TOOL LIST......................................................................................................................................................................................... 955 REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY.................................................................................................................................................. 971 REMOVAL............................................................................................................................................................................................... 971 INSTALLATION.......................................................................................................................................................................................... 972 REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY........................................................................................................................................................ 973 REMOVAL............................................................................................................................................................................................... 973 INSTALLATION.......................................................................................................................................................................................... 973 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY........................................................................................................................................................ 974 SPECIAL TOOL.......................................................................................................................................................................................... 974 REMOVAL............................................................................................................................................................................................... 974 INSTALLATION.......................................................................................................................................................................................... 979 REMOVAL AND INSTALLATION OF ENGINE ADDEMBLY............................................................................................................................................................... 982 SPECIAL TOOL.......................................................................................................................................................................................... 982 REMOVAL............................................................................................................................................................................................... 982 INSTALLATION.......................................................................................................................................................................................... 988 REMOVAL AND INSTALLATION OF AFTER COOLER ASSEMBLY......................................................................................................................................................... 989 REMOVAL............................................................................................................................................................................................... 989 INSTALLATION.......................................................................................................................................................................................... 989 REMOVAL AND INSTALLATION OF RADIATOR, FAN MOTOR AND AFTER COOLER ASSEMBLY................................................................................................................................. 991 REMOVAL............................................................................................................................................................................................... 991 INSTALLATION.......................................................................................................................................................................................... 993 REMOVAL AND INSTALLATION FUEL TANK ASSEMBLY............................................................................................................................................................... 994 REMOVAL .............................................................................................................................................................................................. 994 INSTALLATION.......................................................................................................................................................................................... 995 REMOVAL AND INSTALLATION OF PARKING BRAKE DISC AND PLATE.................................................................................................................................................. 996 SPECIAL TOOL.......................................................................................................................................................................................... 996 REMOVAL............................................................................................................................................................................................... 996 INSTALLATION.......................................................................................................................................................................................... 998 REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY.................................................................................................................................... 999 REMOVAL............................................................................................................................................................................................... 999 INSTALLATION..........................................................................................................................................................................................1003 DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY.........................................................................................................................................................1005 SPECIAL TOOL..........................................................................................................................................................................................1005 DISASSEMBLY...........................................................................................................................................................................................1005 ASSEMBLY..............................................................................................................................................................................................1012 DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH PACK ASSEMBLY ............................................................................................................................................1020 SPECIAL TOOLS.........................................................................................................................................................................................1020 DISASSEMBLY...........................................................................................................................................................................................1020 ASSEMBLY..............................................................................................................................................................................................1026 DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY........................................................................................................................................................1036 SPECIAL TOOLS.........................................................................................................................................................................................1036 DISASSEMBLY...........................................................................................................................................................................................1036 ASSEMBLY..............................................................................................................................................................................................1038 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (STANDARD SPECIFICATION)............................................................................................................................1044 SPECIAL TOOLS.........................................................................................................................................................................................1044 DISASSEMBLY...........................................................................................................................................................................................1044 ASSEMBLY..............................................................................................................................................................................................1046 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY(LOCK-UP SPECIFICATION)..............................................................................................................................1048 SPECIAL TOOLS.........................................................................................................................................................................................1048 DISASSEMBLY...........................................................................................................................................................................................1048 ASSEMBLY..............................................................................................................................................................................................1050 REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY...........................................................................................................................................................1054 REMOVAL...............................................................................................................................................................................................1054 INSTALLATION..........................................................................................................................................................................................1054 REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY............................................................................................................................................................1055 REMOVAL ..............................................................................................................................................................................................1055 INSTALLATION..........................................................................................................................................................................................1057 DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY.........................................................................................................................................................1058 SPECIAL TOOLS.........................................................................................................................................................................................1058 DISASSEMBLY...........................................................................................................................................................................................1058 ASSEMBLY..............................................................................................................................................................................................1061 DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY.........................................................................................................................................................1067 SPECIAL TOOLS.........................................................................................................................................................................................1067 DISASSEMBLY...........................................................................................................................................................................................1067 ASSEMBLY..............................................................................................................................................................................................1073 REMOVAL AND INSTALLATION OF CENTER HING PIN...............................................................................................................................................................1086 SPECIAL TOOL..........................................................................................................................................................................................1086 REMOVAL...............................................................................................................................................................................................1086 INSTALLATION..........................................................................................................................................................................................1090 REMOVAL AND INSTALLATION OF CAB ASSEMBLY..................................................................................................................................................................1094 REMOVAL ..............................................................................................................................................................................................1094 INSTALLATION..........................................................................................................................................................................................1096 REMOVAL AND INSTALLATION OF CAB AND FLOOR FRAME ASSEMBLY..................................................................................................................................................1097 SPECIAL TOOL..........................................................................................................................................................................................1097 REMOVAL...............................................................................................................................................................................................1097 INSTALLATION..........................................................................................................................................................................................1100 REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS(STUCK GLASS).............................................................................................................................................1101 SPECIAL TOOL..........................................................................................................................................................................................1101 REMOVAL...............................................................................................................................................................................................1101 INSTALLATION..........................................................................................................................................................................................1102 COATING MATERIALS.....................................................................................................................................................................................1108 REMOVAL AND INSTALLATION OF TORQUE CONVERTER WORK EQUIPMENT AND PILOT CONTROL PUMP ASSEMBLY...............................................................................................................1109 REMOVAL...............................................................................................................................................................................................1109 INSTALLATION..........................................................................................................................................................................................1109 REMOVAL AND INSTALLATION OF STEERING, SWITCH AND FAN PUMP ASSEMBLY........................................................................................................................................1110 REMOVAL...............................................................................................................................................................................................1110 INSTALLATION..........................................................................................................................................................................................1110 REMOVAL AND INSTALLATION OF STEERING DEMAND VALVE ASSEMBLY................................................................................................................................................1111 REMOVAL ..............................................................................................................................................................................................1111 INSTALLATION..........................................................................................................................................................................................1111 REMOVAL AND INSTALLATION OF TRAVEL DUMPER VALVE ASSEMBLY..................................................................................................................................................1112 REMOVAL...............................................................................................................................................................................................1112 INSTALLATION..........................................................................................................................................................................................1112 REMOVAL AND INSTALLATION OF WORK EQUIPMENT VALVE ASSEMBLY.................................................................................................................................................1113 REMOVAL ..............................................................................................................................................................................................1113 INSTALLATION..........................................................................................................................................................................................1114 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ...............................................................................................................................................................1115 REMOVAL...............................................................................................................................................................................................1115 INSTALLATION..........................................................................................................................................................................................1116 REMOVAL AND INSTALLATION OF HYDRAULIC TANK................................................................................................................................................................1117 REMOVAL ..............................................................................................................................................................................................1117 INSTALLATION..........................................................................................................................................................................................1119 DISASSEMBLY AD ASSEMBLY OF HYDRAULIC CYLINDER.............................................................................................................................................................1123 SPECIAL TOOL..........................................................................................................................................................................................1123 DISASSEMBLY...........................................................................................................................................................................................1123 ASSEMBLY..............................................................................................................................................................................................1126 REMOVAL AND INSTALLATION OF COUNTER WEIGHT................................................................................................................................................................1131 REMOVAL...............................................................................................................................................................................................1131 INSTALLATION..........................................................................................................................................................................................1131 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT..........................................................................................................................................................1132 SPECIAL TOOL..........................................................................................................................................................................................1132 REMOVAL...............................................................................................................................................................................................1132 INSTALLATION..........................................................................................................................................................................................1134 REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY...........................................................................................................................................1135 SPECIAL TOOL..........................................................................................................................................................................................1135 REMOVAL...............................................................................................................................................................................................1135 INSTALLATION..........................................................................................................................................................................................1136 DISASSEMBLY, ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY.........................................................................................................................................................1137 DISASSEMBLY...........................................................................................................................................................................................1137 ASSEMBLY..............................................................................................................................................................................................1142 90 OTHERS.....................................................................................................................................................................................................1147 POWER TRAIN OIL CIRCUIT DIAGRAM(WITHOUT TORQUE CONVERTER LOCKUP CLUTCH)...................................................................................................................................1148 POWER TRAIN OIL CIRCUIT DIAGRAM(WITH TORQUE CONVERTER LOCKUP CLUTCH)......................................................................................................................................1149 BRAKE OIL CIRCUIT DIAGRAM.................................................................................................................................................................................1150 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................................1151 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM(FOR ELECTRIC WORK EQUIPMENT LEVER)...............................................................................................................................1152 ELECTRICAL CIRCUIT DIAGRAM(1/8)(1/4)......................................................................................................................................................................1153 ELECTRICAL CIRCUIT DIAGRAM(1/8)(2/4)......................................................................................................................................................................1154 ELECTRICAL CIRCUIT DIAGRAM(1/8)(3/4)......................................................................................................................................................................1155 ELECTRICAL CIRCUIT DIAGRAM(1/8)(4/4)......................................................................................................................................................................1156 ELECTRICAL CIRCUIT DIAGRAM(2/8)(1/4)......................................................................................................................................................................1157 ELECTRICAL CIRCUIT DIAGRAM(2/8)(2/4)......................................................................................................................................................................1158 ELECTRICAL CIRCUIT DIAGRAM(2/8)(3/4)......................................................................................................................................................................1159 ELECTRICAL CIRCUIT DIAGRAM(2/8)(4/4)......................................................................................................................................................................1160 ELECTRICAL CIRCUIT DIAGRAM(3/8)...........................................................................................................................................................................1161 ELECTRICAL CIRCUIT DIAGRAM(4/8)...........................................................................................................................................................................1162 ELECTRICAL CIRCUIT DIAGRAM(5/8)...........................................................................................................................................................................1163 ELECTRICAL CIRCUIT DIAGRAM(6/8)...........................................................................................................................................................................1164 ELECTRICAL CIRCUIT DIAGRAM(7/8)...........................................................................................................................................................................1165 ELECTRICAL CIRCUIT DIAGRAM(8/8)...........................................................................................................................................................................1166
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