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Komatsu WA450-5L, WA480-5L GALEO Wheel Loader Shop Manual A36001 and up, A37001 and up – DOWNLOAD
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Komatsu WA450-5L, WA480-5L GALEO Wheel Loader Shop Manual
SERIAL NUMBERS:
WA450-5L A36001 and UP
WA480-5L A37001 and UP
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Description
Komatsu WA450-5L, WA480-5L GALEO Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA450-5L, WA480-5L GALEO Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA450-5L, WA480-5L GALEO
Serial Number: A36001 and up, A37001 and up
Book Code: CEBM009605
Language: English
Pages: 1411
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA450-5L, WA480-5L GALEO 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 sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE 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.
TESTING, ADJUSTING AND TROUBLESHOOTING:
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” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu WA450-5L, WA480-5L GALEO Wheel Loader Shop Manual
MAIN MENU................................................................................................................. 0 COVER..................................................................................................................... 1 CONTENTS.................................................................................................................. 2 FOREWORD.................................................................................................................. 15 SAFETY................................................................................................................ 15 SAFETY NOTICE..................................................................................................... 15 IMPORTANT SAFETY NOTICE....................................................................................... 15 GENERAL PRECAUTIONS........................................................................................... 15 PREPARATIONS FOR WORK......................................................................................... 15 PRECAUTIONS DURING WORK....................................................................................... 15 GENERAL............................................................................................................... 17 HOW TO READ THE SHOP MANUAL........................................................................................... 18 VOLUMES........................................................................................................... 18 DISTRIBUTION AND UPDATING......................................................................................... 18 FILING METHOD..................................................................................................... 18 REVISED EDITION MARK.............................................................................................. 18 REVISIONS......................................................................................................... 18 SYMBOLS........................................................................................................... 18 HOISTING INSTRUCTIONS................................................................................................. 19 HOISTING.......................................................................................................... 19 WIRE ROPES........................................................................................................ 19 PUSH PULL COUPLER..................................................................................................... 20 TYPE 1............................................................................................................ 20 TYPE 2............................................................................................................ 21 TYPE 3............................................................................................................ 22 COATING MATERIALS..................................................................................................... 23 STANDARD TIGHTENING TORQUE............................................................................................ 25 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS...................................................................... 25 TIGHTENING TORQUE OF HOSE NUTS.................................................................................... 26 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS........................................................................... 26 TIGHTENING TORQUE FOR FLARED NUTS................................................................................. 26 ELECTRIC WIRE CODE.................................................................................................... 27 CLASSIFICATION BY THICKNESS....................................................................................... 27 CLASSIFICATION BY COLOR AND CODE.................................................................................. 27 CONVERSION TABLES..................................................................................................... 28 METHOD OF USING THE CONVERSION TABLE.............................................................................. 28 01 GENERAL................................................................................................................ 35 SPECIFICATIONS........................................................................................................ 36 WEIGHT TABLE.......................................................................................................... 40 FUEL, COOLANT AND LUBRICANTS.......................................................................................... 41 10 STRUCTURE AND FUNCTION................................................................................................. 43 RADIATOR AND OIL COOLER............................................................................................... 51 SPECIFICATIONS.................................................................................................... 51 ENGINE AND TRANSMISSION MOUNT......................................................................................... 52 POWER TRAIN........................................................................................................... 53 OUTLINE........................................................................................................... 53 POWER TRAIN SYSTEM DIAGRAM............................................................................................ 54 WITHOUT TORQUE CONVERTER LOCK UP CLUTCH........................................................................... 54 WITH TORQUE CONVERTER LOCK UP CLUTCH.............................................................................. 55 DRIVE SHAFT........................................................................................................... 57 DRIVE TRAIN PIPING.................................................................................................... 58 TORQUE CONVERTER...................................................................................................... 59 WITHOUT LOCK UP CLUTCH............................................................................................ 59 SPECIFICATIONS................................................................................................ 59 PATH OF POWER TRANSMISSION.................................................................................... 61 WITH LOCK UP CLUTCH............................................................................................... 62 SPECIFICATIONS................................................................................................ 62 PATH OF POWER TRANSMISSION.................................................................................... 66 TRANSMISSION.......................................................................................................... 68 OUTLINE........................................................................................................... 73 CLUTCH AND REDUCTION GEAR RATIO TABLE............................................................................. 73 F & R CLUTCH WITHOUT LOCK UP CLUTCH............................................................................... 74 F & R CLUTCH WITH LOCK UP CLUTCH.................................................................................. 75 1ST & 4TH CLUTCH.................................................................................................. 76 2ND & 3RD CLUTCH.................................................................................................. 77 OPERATION OF CLUTCH............................................................................................... 78 CLUTCH ENGAGED................................................................................................ 78 CLUTCH DISENGAGED............................................................................................. 78 FORWARD 1ST................................................................................................... 79 FORWARD 2ND................................................................................................... 80 FORWARD 3RD................................................................................................... 81 FORWARD 4TH................................................................................................... 82 REVERSE 1ST................................................................................................... 83 TRANSMISSION CONTROL VALVE............................................................................................ 84 WITHOUT LOCK UP CLUTCH............................................................................................ 84 ECMV ACTUATION TABLE.......................................................................................... 85 OUTLINE....................................................................................................... 85 WITH LOCK UP CLUTCH............................................................................................... 86 ECMV ACTUATION TABLE.......................................................................................... 87 OUTLINE....................................................................................................... 87 ECMV - ELECTRONIC CONTROL MODULATION VALVE........................................................................ 88 ECMV FOR SPEED CLUTCH......................................................................................... 89 ECMV FOR LOCK UP CLUTCH....................................................................................... 92 MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE........................................................................ 94 OUTLINE....................................................................................................... 95 OPERATION..................................................................................................... 95 FLOW VALVE........................................................................................................ 96 OPERATION..................................................................................................... 96 AXLES................................................................................................................. 97 FRONT AXLE........................................................................................................ 97 WA450-5L...................................................................................................... 97 WA480-5L...................................................................................................... 98 REAR AXLE......................................................................................................... 99 WA450-5L...................................................................................................... 99 WA480-5L...................................................................................................... 100 AXLE MOUNTING......................................................................................................... 101 FRONT AXLE........................................................................................................ 101 REAR AXLE......................................................................................................... 102 DIFFERENTIAL.......................................................................................................... 103 LIMITED SLIP DIFFERENTIAL......................................................................................... 103 WA450-5L FRONT................................................................................................ 105 WA480-5L FRONT AND REAR....................................................................................... 105 WA450-5L REAR................................................................................................. 106 OPERATION..................................................................................................... 107 TRAVELING IN A STRAIGHT LINE.................................................................................. 107 WHEN TURNING.................................................................................................. 108 STANDARD DIFFERNTIAL.............................................................................................. 109 FRONT DIFFERENTIAL............................................................................................ 109 REAR DIFFERENTIAL............................................................................................. 110 OUTLINE....................................................................................................... 111 TRAVELING IN A STRAIGHT LINE.................................................................................. 111 TURNING....................................................................................................... 111 FINAL DRIVE........................................................................................................... 112 WA450-5L.......................................................................................................... 112 WA480-5L.......................................................................................................... 113 OUTLINE........................................................................................................... 115 CENTER HINGE PIN...................................................................................................... 116 OUTLINE........................................................................................................... 116 STEERING PIPING....................................................................................................... 119 STEERING COLUMN....................................................................................................... 120 STEERING VALVE........................................................................................................ 121 OVERLOAD RELIEF VALVE............................................................................................. 122 FUNCTION...................................................................................................... 122 OPERATION..................................................................................................... 122 STEERING RELIEF VALVE............................................................................................. 123 FUNCTION...................................................................................................... 123 OPERATION OF STEERING RELIEF VALVE............................................................................ 124 OPERATION OF DEMAND VALVE..................................................................................... 125 FLOW AMP.......................................................................................................... 128 OPERATION OF FLOW AMP......................................................................................... 128 OPERATION OF STEERING VALVE....................................................................................... 131 NEUTRAL....................................................................................................... 131 TURNING RIGHT................................................................................................. 132 TURNING LEFT.................................................................................................. 133 ORBITROL VALVE........................................................................................................ 134 OUTLINE........................................................................................................... 135 STRUCTURE......................................................................................................... 135 CONNECTION BETWEEN HAND PUMP AND SLEEVE........................................................................... 136 STOP VALVE............................................................................................................ 138 STEERING AND SWITCH PUMP.............................................................................................. 139 OUTLINE........................................................................................................... 139 AUXILIARY STEERING PUMP............................................................................................... 141 FUNCTION.......................................................................................................... 141 AUXILIARY STEERING MOTOR.............................................................................................. 142 FUNCTION.......................................................................................................... 142 SPECIFICATIONS.................................................................................................... 142 STEERING CYLINDER..................................................................................................... 143 MOUNTING.......................................................................................................... 143 CYLINDER.......................................................................................................... 144 JOYSTICK STEERING LEVER............................................................................................... 145 LEVER CONNECTIONS................................................................................................. 145 STEERING SWITCH VALVE............................................................................................. 146 OPERATION..................................................................................................... 146 STEERING LEVER VALVE.............................................................................................. 147 BRAKE SYSTEM.......................................................................................................... 148 PIPING............................................................................................................ 148 BRAKE VALVE....................................................................................................... 149 LEFT PEDAL AND VALVE.......................................................................................... 149 RIGHT PEDAL AND VALVE......................................................................................... 150 OUTLINE....................................................................................................... 151 OPERATION..................................................................................................... 151 CHARGE VALVE...................................................................................................... 155 FUNCTION...................................................................................................... 156 OPERATION..................................................................................................... 157 ACCUMULATOR....................................................................................................... 159 BETWEEN CHARGE VALVE AND BRAKE VALVE.......................................................................... 159 SPECIFICATIONS................................................................................................ 159 BETWEEN BRAKE VALVE AND BRAKE CYLINDER........................................................................ 160 SLACK ADJUSTER.................................................................................................... 161 OUTLINE....................................................................................................... 162 SPECIFICATIONS................................................................................................ 162 OPERATION..................................................................................................... 163 BRAKES............................................................................................................ 164 FRONT......................................................................................................... 164 REAR.......................................................................................................... 165 PARKING BRAKE......................................................................................................... 167 CONTROLS.......................................................................................................... 167 OUTLINE....................................................................................................... 167 BRAKE PORTION..................................................................................................... 168 OUTLINE....................................................................................................... 168 SOLENOID VALVE.................................................................................................... 169 PARKING BRAKE APPLIED......................................................................................... 169 PARKING BRAKE RELEASED........................................................................................ 169 RELEASE VALVE..................................................................................................... 170 OUTLINE....................................................................................................... 170 HYDRAULIC PIPING...................................................................................................... 171 OUTLINE........................................................................................................... 172 WORK EQUIPMENT CONTROL LEVER.......................................................................................... 173 FOR PPC VALVE..................................................................................................... 173 FOR EPC VALVE..................................................................................................... 174 HYDRAULIC TANK........................................................................................................ 175 SPECIFICATIONS.................................................................................................... 175 BREATHER.......................................................................................................... 176 SPECIFICATIONS................................................................................................ 176 PREVENTION OF NEGATIVE PRESSURE IN TANK....................................................................... 176 PREVENTION OF PRESSURE RISE IN TANK........................................................................... 176 CONVERTER, EQUIPMENT AND PPC PUMPS.................................................................................... 177 SAL (4)125+140+(1)22.............................................................................................. 177 OUTLINE........................................................................................................... 177 PPC RELIEF VALVE...................................................................................................... 178 OUTLINE........................................................................................................... 178 OPERATION......................................................................................................... 178 ECSS VALVE............................................................................................................ 179 ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM....................................................................... 179 TRAVEL DAMPER VALVE................................................................................................... 181 EQUIPMENT CONTROL VALVE............................................................................................... 182 2 SPOOL VALVE..................................................................................................... 182 3 SPOOL VALVE..................................................................................................... 185 RELIEF VALVE...................................................................................................... 188 FUNCTION...................................................................................................... 188 OPERATION..................................................................................................... 188 SAFETY SUCTION VALVE.............................................................................................. 189 FUNCTION...................................................................................................... 189 OPERATION..................................................................................................... 189 SUCTION VALVE..................................................................................................... 190 FUNCTION...................................................................................................... 190 OPERATION..................................................................................................... 190 SAFETY SUCTION VALVE.............................................................................................. 190 FUNCTION...................................................................................................... 190 OPERATION..................................................................................................... 190 CUT OFF VALVE..................................................................................................... 192 FUNCTION...................................................................................................... 192 CUT OFF VALVE OPERATION....................................................................................... 192 FLOAT SELECTOR AND UNLOAD VALVE................................................................................... 194 FUNCTION...................................................................................................... 194 OPERATION..................................................................................................... 194 BOOM AND BUCKET SPOOL HOLD POSITION............................................................................... 195 OPERATION..................................................................................................... 195 BOOM SPOOL RAISE POSITION......................................................................................... 196 OPERATION..................................................................................................... 196 BOOM SPOOL LOWER POSITION......................................................................................... 197 OPERATION..................................................................................................... 197 BOOM SPOOL FLOAT POSITION......................................................................................... 198 OPERATION..................................................................................................... 198 BUCKET SPOOL DUMP POSITION........................................................................................ 199 OPERATION..................................................................................................... 199 BUCKET SPOOL TILT POSITION........................................................................................ 200 OPERATION..................................................................................................... 200 PPC VALVE FOR TWO LEVERS.............................................................................................. 201 OPERATION......................................................................................................... 203 NEUTRAL....................................................................................................... 203 FINE CONTROL MODE............................................................................................. 204 PPC VALVE FOR MONO LEVER.............................................................................................. 206 OPERATION......................................................................................................... 208 NEUTRAL....................................................................................................... 208 FINE CONTROL.................................................................................................. 209 FLOAT......................................................................................................... 210 FLOAT RELEASED................................................................................................ 210 EPC VALVE............................................................................................................. 211 FUNCTION.......................................................................................................... 212 OPERATION......................................................................................................... 212 SHUT OFF VALVE........................................................................................................ 214 FUNCTION.......................................................................................................... 214 COOLING FAN........................................................................................................... 215 MOTOR MODEL: LMF28................................................................................................ 215 SPECIFICATIONS................................................................................................ 215 FUNCTION...................................................................................................... 217 PRINCIPLE OF OPERATION........................................................................................ 217 SUCTION VALVE..................................................................................................... 218 FUNCTION...................................................................................................... 218 OPERATION..................................................................................................... 218 FAN DIRECTION CHANGEOVER VALVE................................................................................ 219 DRIVE PUMP - MODEL: LPV3O......................................................................................... 220 FUNCTION...................................................................................................... 222 STRUCTURE..................................................................................................... 222 OPERATION..................................................................................................... 223 SERVO VALVE....................................................................................................... 224 FUNCTION...................................................................................................... 225 SAFETY VALVE...................................................................................................... 226 FUNCTION...................................................................................................... 226 BOOM AND BUCKET LINKAGE............................................................................................... 227 BUCKET................................................................................................................ 229 BUCKET POSITIONER, BOOM KICK OUT...................................................................................... 230 BUCKET POSITIONER................................................................................................. 231 BOOM KICK OUT..................................................................................................... 231 OPERATION OF PROXIMITY SWITCH..................................................................................... 231 BOOM RAISE.................................................................................................... 231 BUCKET TILT................................................................................................... 233 WORK EQUIPMENT CYLINDER............................................................................................... 236 BOOM CYLINDER..................................................................................................... 236 BUCKET CYLINDER................................................................................................... 236 CAB................................................................................................................... 238 AIR CONDITIONER....................................................................................................... 239 MACHINE MONITORING SYSTEM............................................................................................. 240 OUTLINE........................................................................................................... 240 MODE INDICATIONS.............................................................................................. 240 INDIVIDUAL CIRCUIT DIAGRAMS....................................................................................... 242 STARTING AND LIGHTING......................................................................................... 242 LOAD METER.................................................................................................... 242 SENSING FUNCTIONS............................................................................................. 243 POWER SUPPLY AND NETWORK...................................................................................... 244 MACHINE MONITOR....................................................................................................... 248 STANDARD STYLE.................................................................................................... 248 LOAD METER STYLE.................................................................................................. 249 TABLE OF MONITOR INDICATION ITEMS................................................................................. 250 SETTING OF THE MACHINE MONITOR.................................................................................... 260 ADJUSTMENT PROCEDURES......................................................................................... 262 SERVICE MODE FUNCTIONS........................................................................................ 263 ITEMS RELATED TO THE FAULT HISTORY OF ELECTRIC SYSTEM......................................................... 267 ITEMS RELATED TO THE FAULT HISTORY OF MACHINE SYSTEM.......................................................... 269 ITEMS RELATED TO MAINTENANCE MONITOR.......................................................................... 271 ENGINE CYLINDER CUT OUT FUNCTION.............................................................................. 273 REAL TIME MONITORING FUNCTION................................................................................. 275 REAL TIME MONITORING ITEMS.................................................................................... 279 LOAD METER FUNCTION........................................................................................... 290 OUTLINE....................................................................................................... 290 MACHINE SETTING............................................................................................... 299 TRANSMISSION CONTROL SYSTEM........................................................................................... 327 CONTROL FUNCTION.................................................................................................. 328 ELECTRIC CIRCUIT DIAGRAM - STD.................................................................................... 352 ELECTRIC CIRCUIT DIAGRAM - OPT.................................................................................... 354 TRANSMISSION CONTROLLER............................................................................................... 356 INPUT AND OUTPUT SIGNALS.......................................................................................... 356 DEUTSCH-24P - CNL61........................................................................................... 356 DEUTSCH-40P[1] - CNL62........................................................................................ 357 DEUTSCH-40P[2] - CNL63........................................................................................ 357 WORK EQUIPMENT CONTROL SYSTEM......................................................................................... 358 SYSTEM DIAGRAM.................................................................................................... 358 WORK EQUIPMENT CONTROL............................................................................................ 359 ELECTRIC LEVER CONTROL........................................................................................ 359 DETENT CONTROL................................................................................................ 360 REMOTE POSITIONER CONTROL......................................................................................... 362 FUNCTIONS..................................................................................................... 362 STOP THE BOOM RAISE OPERATION................................................................................. 362 CONTROL ITEMS................................................................................................. 364 SEMI AUTO DIG CONTROL............................................................................................. 365 STARTING CONDITIONS FOR SEMI AUTO DIG......................................................................... 366 STARTING SEMI AUTO DIG........................................................................................ 366 TERMINATION OF SEMI AUTO DIG.................................................................................. 366 SEMI AUTO DIG MODE............................................................................................ 367 JOYSTICK STEERING CONTROL......................................................................................... 368 STEERING CONTROL.............................................................................................. 369 MODULATION CONTROL............................................................................................ 369 CALIBRATION FUNCTION.......................................................................................... 370 ELECTRIC CIRCUIT DIAGRAM.......................................................................................... 371 WORK EQUIPMENT CONTROLLER............................................................................................. 373 INPUT AND OUTPUT SIGNALS.......................................................................................... 373 DEUTSCH-24P - CNL71........................................................................................... 373 DEUTSCH-40P[1] - CNL72........................................................................................ 374 DEUTSCH-40P[2] - CNL73........................................................................................ 374 ELECTRIC TRANSMISSION CONTROL......................................................................................... 375 FUNCTIONS......................................................................................................... 376 COMBINATION SWITCH................................................................................................ 377 FUNCTIONS..................................................................................................... 377 OVERVIEW...................................................................................................... 377 OPERATION..................................................................................................... 378 KICK DOWN HOLD SWITCH................................................................................................. 379 FUNCTIONS......................................................................................................... 379 ENGINE START CIRCUIT.................................................................................................. 380 FUNCTION.......................................................................................................... 380 OPERATION......................................................................................................... 381 ENGINE STOP CIRCUIT................................................................................................... 382 OPERATION......................................................................................................... 382 PARKING BRAKE CIRCUIT................................................................................................. 383 OPERATION......................................................................................................... 383 STARTING SWITCH IN OFF POSITION............................................................................... 383 STARTING SWITCH IN ON POSITION................................................................................ 383 TURN SIGNAL AND HAZARD LAMP CIRCUIT................................................................................... 385 OPERATION......................................................................................................... 385 STARTING SWITCH IN OFF POSITION............................................................................... 385 STARTING SWITCH IN ON POSITION................................................................................ 385 BACK UP LAMP AND STOP LAMP CIRCUIT.................................................................................... 387 OPERATION......................................................................................................... 387 STOP LAMP CIRCUIT............................................................................................. 387 BACK UP LAMP CIRCUIT.......................................................................................... 388 SMALL LAMP AND HEAD LAMP CIRCUIT...................................................................................... 389 OPERATION......................................................................................................... 389 WORK LAMP CIRCUIT..................................................................................................... 390 OPERATION......................................................................................................... 390 HORN CIRCUIT.......................................................................................................... 391 OPERATION......................................................................................................... 391 WIPER WASHER CIRCUIT.................................................................................................. 392 OPERATION......................................................................................................... 392 FRONT WIPER CIRCUIT........................................................................................... 392 REAR WIPER CIRCUIT............................................................................................ 393 SENSORS............................................................................................................... 394 ENGINE AND MACHINE SPEED SENSOR................................................................................... 394 FUNCTION...................................................................................................... 394 ENGINE OIL PRESSURE SENSOR........................................................................................ 394 FUNCTION...................................................................................................... 394 ENGINE OIL LEVEL SENSOR........................................................................................... 395 FUNCTION...................................................................................................... 395 TEMPERATURE SENSOR................................................................................................ 395 ENGINE COOLANT, CONVERTER, HYDRAULIC, TRANSMISSION OR BRAKE OIL............................................... 395 TRANSMISSION CUT OFF PRESSURE SENSOR.............................................................................. 396 FUNCTION...................................................................................................... 396 RADIATOR COOLANT LEVEL SENSOR..................................................................................... 397 FUNCTION...................................................................................................... 397 FUEL LEVEL SENSOR................................................................................................. 398 FUNCTION...................................................................................................... 398 BOOM ANGLE SENSOR FOR LOAD METER.................................................................................. 399 FUNCTION...................................................................................................... 399 AIR CLEANER CLOGGING SENSOR....................................................................................... 400 FUNCTION...................................................................................................... 400 PRESSURE SENSOR FOR LOAD METER.................................................................................... 400 FUNCTION...................................................................................................... 400 BATTERY LIQUID SENSOR............................................................................................. 401 FUNCTION...................................................................................................... 401 RELAYS................................................................................................................ 402 20 TESTING, ADJUSTING AND TROUBLESHOOTING................................................................................. 403 STANDARD VALUE TABLE FOR ENGINE....................................................................................... 405 STANDARD VALUE TABLE FOR CHASSIS...................................................................................... 406 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING...................................................................... 413 ENGINE COMPONENTS..................................................................................................... 415 MEASURING EXHAUST SMOKE........................................................................................... 415 MEASURING EXHAUST TEMPERATURE..................................................................................... 415 ADJUSTING VALVE CLEARANCE......................................................................................... 415 MEASURING COMPRESSION PRESSURE.................................................................................... 415 MEASURING CRANCASE PRESSURE....................................................................................... 415 MEASURING ENGINE OIL PRESSURE..................................................................................... 415 MEASURING BOOST PRESSURE.......................................................................................... 415 MEASURING FUEL PRESSURE........................................................................................... 415 ADJUSTING ENGINE SPEED SENSOR..................................................................................... 415 BLEEDING AIR FROM FUEL SYSTEM..................................................................................... 415 MEASURING ENGINE SPEED............................................................................................ 416 ADJUSTING ACCELERATOR PEDAL........................................................................................... 418 POTENTIOMETER..................................................................................................... 418 MICROSWITCH....................................................................................................... 420 ADJUSTING TRANSMISSION SPEED SENSOR................................................................................... 421 POWER TRAIN OIL PRESSURE.............................................................................................. 422 FLUSHING.............................................................................................................. 426 TORQUE CONVERTER, TRANSMISSION AND HYDRAULIC CIRCUIT.............................................................. 426 TRANSMISSION VALVE FAILS.............................................................................................. 427 MOVING MACHINE.................................................................................................... 427 STEERING CONTROL...................................................................................................... 429 STEERING OIL PRESSURE................................................................................................. 430 BRAKE SYSTEM.......................................................................................................... 432 MEASURING BRAKE OIL PRESSURE...................................................................................... 432 TESTING WEAR OF WHEEL BRAKE DISC.................................................................................. 434 BLEEDING AIR FROM BRAKE CIRCUIT................................................................................... 435 TESTING WEAR OF PARKING BRAKE DISC................................................................................ 436 MANUAL RELEASE METHOD FOR PARKING BRAKE........................................................................... 437 TESTING HYDRAULIC FAN................................................................................................. 438 ACCUMULATOR CHARGE PRESSURE........................................................................................... 439 PPC OIL PRESSURE...................................................................................................... 441 WORK EQUIPMENT HYDRAULIC PRESSURE..................................................................................... 444 BUCKET POSITIONER..................................................................................................... 446 LIFT ARM KICK-OUT..................................................................................................... 447 PROXIMITY SWITCH ACTUATION............................................................................................ 448 ADJUSTING MACHINE MONITOR............................................................................................. 449 LOAD METER............................................................................................................ 452 LOAD METER CALIBRATION................................................................................................ 453 NO LOAD ZERO POINT ADJUSTMENT (SUPPLEMENTAL EXPLANATIONS)......................................................... 453 LOAD ZERO POINT ADJUSTMENT (SUPPLEMENTARY EXPLANATIONS)........................................................... 454 BLEEDING AIR.......................................................................................................... 457 RELEASING REMAINING PRESSURE.......................................................................................... 458 IN HYDRAULIC CIRCUIT.............................................................................................. 458 IN TRAVEL DAMPER CIRCUIT.......................................................................................... 459 HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT.............................................................................. 460 PM-CLINIC INSPECTION TABLE............................................................................................ 461 TROUBLESHOOTING GENERAL............................................................................................... 465 POINTS TO REMEMBER WHEN TROUBLESHOOTING........................................................................... 466 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................. 468 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE......................................................................... 469 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT.................................................................. 469 HANDLING CONTROL BOX.......................................................................................... 474 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.......................................................... 475 CHECKS BEFORE TROUBLESHOOTING..................................................................................... 477 EQUIPMENT FOR TROUBLESHOOTING ELECTRICAL SYSTEM................................................................... 478 TROUBLESHOOTING MACHINE MONITOR....................................................................................... 479 SPECIAL FUNCTIONS OF MACHINE MONITOR.............................................................................. 480 FLOW OF MODES AND FUNCTIONS................................................................................... 481 FAILURE CODE TABLE............................................................................................ 489 MONITORING CODE TABLE......................................................................................... 503 USING TROUBLESHOOTING CHARTS...................................................................................... 515 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS........................................................................ 522 T-ADAPTER TABLE................................................................................................... 543 TROUBLESHOOTING OF ENGINE CONTROL SYSTEM (ENG MODE)................................................................... 547 CONNECTOR TYPES AND INSTALLATION LOCATIONS........................................................................ 550 CONNECTOR ARRANGEMENT LOCATIONS................................................................................... 557 ENGINE CONTROL SYSTEM DIAGRAM..................................................................................... 563 ERROR CODE [A000N1]............................................................................................... 565 ENGINE OVERRUNS (N1).......................................................................................... 565 ERROR CODE [AD00L2]............................................................................................... 566 COMMON RAIL HIGHER THAN SET VALUE............................................................................. 566 ERROR CODE [AD10L3]............................................................................................... 567 FUEL SUPPLY PUMP CANNOT BE CONTROLLED......................................................................... 567 ERROR CODE [AD00MA]............................................................................................... 570 FUNCTION OF COMMON RAIL IS DEFECTIVE.......................................................................... 570 ERROR CODE [AD10MA]............................................................................................... 571 FUEL SUPPLY PUMP IS DEFECTIVE................................................................................. 571 ERROR CODE [AD10MB]............................................................................................... 572 FUEL SUPPLY PUMP FLOW LOWERED................................................................................. 572 ERROR CODE [AD11KA or AD11KB]..................................................................................... 573 OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM................................................................. 573 ERROR CODE [AD51KA or AD51KB]..................................................................................... 575 OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM................................................................. 575 ERROR CODE [ADA1KA]............................................................................................... 577 OPEN IN NO. 1 INJECTOR SOLENOID VALVE......................................................................... 577 ERROR CODE [ADAZKB]............................................................................................... 579 SHORT CIRCUIT IN NO. 1, 2, 3 INJECTOR SOLENOID VALVE.......................................................... 579 ERROR CODE [ADB1KA]............................................................................................... 581 OPEN IN NO. 2 INJECTOR SOLENOID VALVE......................................................................... 581 ERROR CODE [ADC1KA]............................................................................................... 583 OPEN IN NO. 3 INJECTOR SOLENOID VALVE......................................................................... 583 ERROR CODE [ADD1KA]............................................................................................... 585 OPEN IN NO. 4 INJECTOR SOLENOID VALVE......................................................................... 585 ERROR CODE [ADDZKB]............................................................................................... 587 SHORT CIRCUIT IN NO. 4, 5, 6 INJECTOR SOLENOID VALVE.......................................................... 587 ERROR CODE [ADE1KA]............................................................................................... 589 OPEN IN NO. 5 INJECTOR SOLENOID VALVE......................................................................... 589 ERROR CODE [ADF1KA]............................................................................................... 591 OPEN IN NO. 6 INJECTOR SOLENOID VALVE......................................................................... 591 ERROR CODE [D182KZ]............................................................................................... 593 OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL............................................................... 593 ERROR CODE [D1D0KB]............................................................................................... 595 SHORT CIRCUIT IN VOLTAGE LOAD POWER SUPPLY.................................................................... 595 ERROR CODE [DB20KT]............................................................................................... 597 CONTROLLER POWER SUPPLY (NSW) VOLTAGE IS LOW.................................................................. 597 ERROR CODE [AB20KT]............................................................................................... 599 TROUBLE IN DRIVE CIRCUIT IN CONTROLLER........................................................................ 599 ERROR CODE [DB22KK]............................................................................................... 601 ENGINE CONTROLLER LOAD POWER SUPPLY (SW) 1.................................................................... 601 ERROR CODE [DB29KQ]............................................................................................... 603 NONCONFORMANCE OF MODEL SELECTION SIGNALS IN ENGINE CONTROLLER CONNECTING WIRING HARNESS...................... 603 ERROR CODE [DB2AMA]............................................................................................... 605 FUNCTION OF Q ADJUSTMENT SWITCH OF ENGINE CONTROLLER IS DEFECTIVE............................................. 605 ERROR CODE [DD11KB]............................................................................................... 606 TROUBLE IN INPUT OF STARTING SWITCH C (IGN C1)................................................................ 606 ERROR CODE [DGE3L6]............................................................................................... 608 TROUBLE IN WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM.................................................. 608 ERROR CODE [DGE4KX]............................................................................................... 610 TROUBLE IN FUEL TEMPERATURE SENSOR SYSTEM..................................................................... 610 ERROR CODE [DH30KX]............................................................................................... 612 TROUBLE IN BOOST PRESSURE SENSOR SYSTEM....................................................................... 612 ERROR CODE [DH40KX]............................................................................................... 614 TROUBLE IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM............................................................ 614 ERROR CODE [DK10KX]............................................................................................... 616 TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM.............................................................. 616 ERROR CODE [DLE3LC]............................................................................................... 618 TROUBLE IN ENGINE NE SPEED SENSOR SYSTEM...................................................................... 618 ERROR CODE [DLH1LC]............................................................................................... 619 TROUBLE IN ENGINE G SPEED SENSOR SYSTEM....................................................................... 619 ERROR CODE [ENG-1]................................................................................................ 620 ENGINE DOES NOT START......................................................................................... 620 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE)........................................................... 625 CONNECTOR TYPES AND INSTALLATION POSITIONS........................................................................ 631 CONNECTOR LAYOUT DRAWING.......................................................................................... 638 TRANSMISSION RELATED SYSTEM DIAGRAM............................................................................... 644 ERROR CODE [1500L1]............................................................................................... 647 DOUBLE ENGAGEMENT DETECTED.................................................................................... 647 ERROR CODE [15SAL1]............................................................................................... 648 F-ECMV FILL SWITCH SYSTEM SHORTED............................................................................. 648 ERROR CODE [15SALH]............................................................................................... 649 F_ECMV FILL SWITCH SYSTEM OPEN................................................................................ 649 ERROR CODE [15SBL1]............................................................................................... 650 R_ECMV FILL SWITCH SYSTEM SHORTED............................................................................. 650 ERROR CODE [15SBLH]............................................................................................... 652 R_ECMV FILL SWITCH SYSTEM OPEN................................................................................ 652 ERROR CODE [15SEL1]............................................................................................... 653 1ST_ECMV FILL SWITCH SYSTEM SHORTED........................................................................... 653 ERROR CODE [15SELH]............................................................................................... 655 1ST_ECMV FILL SWITCH SYSTEM OPEN.............................................................................. 655 ERROR CODE [15SFL1]............................................................................................... 657 2ND_ECMV FILL SWITCH SYSTEM SHORTED........................................................................... 657 ERROR CODE [15SFLH]............................................................................................... 659 2ND_ECMV FILL SWITCH SYSTEM OPEN.............................................................................. 659 ERROR CODE [15SGL1]............................................................................................... 661 3RD_ECMV FILL SWITCH SYSTEM SHORTED........................................................................... 661 ERROR CODE [15SGLH]............................................................................................... 663 3RD_ECMV FILL SWITCH SYSTEM OPEN.............................................................................. 663 ERROR CODE [15SHL1]............................................................................................... 665 4TH_ECMV FILL SWITCH SYSTEM SHORTED........................................................................... 665 ERROR CODE [15SHLH]............................................................................................... 667 4TH_ECMV FILL SWITCH SYSTEM OPEN.............................................................................. 667 ERROR CODE [15SJL1]............................................................................................... 669 LOCKUP_ECMV FILL SWITCH SYSTEM SHORTED........................................................................ 669 ERROR CODE [15SJLH]............................................................................................... 670 LOCKUP_ECMV FILL SWITCH SYSTEM OPEN........................................................................... 670 ERROR CODE [989F00]............................................................................................... 671 TRANSMISSION PROTECTION CAUTION............................................................................... 671 ERROR CODE [989G00]............................................................................................... 672 FNR LEVER PRIORITY CAUTION.................................................................................... 672 ERROR CODE [B@C7NS]............................................................................................... 673 REAR BRAKE COOLING OIL OVERHEATING FAULT...................................................................... 673 ERROR CODE [D150KA]............................................................................................... 675 EMERGENCY STEERING RELAY OUTPUT SYSTEM OPEN................................................................... 675 ERROR CODE [D150KB]............................................................................................... 676 EMERGENCY STEERING RELAY OUTPUT SYSTEM SHORTED................................................................ 676 ERROR CODE [D160KA]............................................................................................... 677 EMERGENCY STEERING RELAY OUTPUT SYSTEM OPEN................................................................... 677 ERROR CODE [D160KB]............................................................................................... 678 BACKUP LAMP RELAY OUTPUT SYSTEM SHORTED....................................................................... 678 ERROR CODE [D191KA]............................................................................................... 679 NEUTRAL SAFETY RELAY OUTPUT SYSTEM OPEN....................................................................... 679 ERROR CODE [D191KB]............................................................................................... 681 NEUTRAL SAFETY RELAY OUTPUT SYSTEM SHORTED.................................................................... 681 ERROR CODE [D192KA]............................................................................................... 683 BOOM DAMPER RELAY OUTPUT SYSTEM OPEN.......................................................................... 683 ERROR CODE [D192KB]............................................................................................... 684 LIFT ARM DAMPER RELAY OUTPUT SYSTEM SHORTED................................................................... 684 ERROR CODE [DAQ0KK]............................................................................................... 685 CONTROLLER POWER SUPPLY FAULT................................................................................. 685 ERROR CODE [DAQ2KK]............................................................................................... 686 DEFECTIVE SOLENOID POWER SUPPLY SYSTEM........................................................................ 686 ERROR CODE [DAQ9KQ]............................................................................................... 688 MODEL SELECTION SIGNAL MISMATCH............................................................................... 688 ERROR CODE [DDK3KA]............................................................................................... 689 RIGHT FNR SIGNAL INPUT FAULT.................................................................................. 689 ERROR CODE [DDK3KB]............................................................................................... 691 MULTIPLE RIGHT FNR SIGNAL INPUT FAULTS........................................................................ 691 ERROR CODE [DDK6KA]............................................................................................... 693 FORWARD-REVERSE LEVER SIGNAL FAULT............................................................................ 693 ERROR CODE [DDK6KB]............................................................................................... 695 MULTIPLE FORWARD-REVERSE LEVER SIGNAL INPUT FAULT............................................................. 695 ERROR CODE [DDS5KA]............................................................................................... 697 STEERING PRESSURE SWITCH OPEN................................................................................. 697 ERROR CODE [DDS5KB]............................................................................................... 698 STEERING PRESSURE SWITCH SHORTED.............................................................................. 698 ERROR CODE [DDT0L4]............................................................................................... 700 MANUAL/AUTO-SHIFT SELECTOR SWITCH SELECTION FAILURE........................................................... 700 ERROR CODE [DDT4LD]............................................................................................... 702 GROUND FAULT ON TRANSMISSION CUT-OFF SETTING SWITCH........................................................... 702 ERROR CODE [DDW9LD]............................................................................................... 703 SHORT IN KICKDOWN SWITCH SYSTEM............................................................................... 703 ERROR CODE [DDWLLD]............................................................................................... 704 GROUND FAULT IN HOLD SWITCH SYSTEM............................................................................ 704 ERROR CODE [DF10KA]............................................................................................... 705 NO INPUT IN GEAR SHIFT LEVER SYSTEM........................................................................... 705 ERROR CODE [DF10KB]............................................................................................... 707 MULTIPLE GEAR SHIFT LEVER SIGNALS OR NO GEAR SHIFT LEVER SIGNAL............................................... 707 ERROR CODE [DGF1KX]............................................................................................... 709 TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM FAILURE............................................................ 709 ERROR CODE [DGR2KA]............................................................................................... 710 REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM OPEN................................................................. 710 ERROR CODE [DGR2KB]............................................................................................... 712 GROUND FAULT IN REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM...................................................... 712 ERROR CODE [DHT1KX]............................................................................................... 713 TRANSMISSION CUT-OFF (LEFT BRAKE PRESSURE SENSOR) SIGNAL OPEN................................................. 713 ERROR CODE [DLE2KA]............................................................................................... 714 ENGINE SPEED SENSOR OPEN...................................................................................... 714 ERROR CODE [DLE2LC]............................................................................................... 715 ENGINE SPEED SENSOR SHORTED................................................................................... 715 ERROR CODE [DLT3KA]............................................................................................... 716 SPEED SENSOR SYSTEM OPEN...................................................................................... 716 ERROR CODE [DT20KB]............................................................................................... 717 GROUND FAULT IN BUILT-IN INDICATOR LAMP SYSTEM ON TRANSMISSION CUT-OFF SWITCH................................. 717 ERROR CODE [DW7BKA]............................................................................................... 718 FAN REVERSE SOLENOID SYSTEM OPEN.............................................................................. 718 ERROR CODE [DW7BKB]............................................................................................... 719 FAN REVERSE SOLENOID SYSTEM SHORTED........................................................................... 719 ERROR CODE [DW7CKA]............................................................................................... 720 SWITCH PUMP CUT-OFF RELAY OPEN................................................................................ 720 ERROR CODE [DW7CKB]............................................................................................... 721 SWITCH PUMP CUT-OFF RELAY GROUND FAULT........................................................................ 721 ERROR CODE [DX16KA]............................................................................................... 722 FAN PUMP EPC SOLENOID SYSTEM OPEN............................................................................. 722 ERROR CODE [DX16KB]............................................................................................... 723 FAN PUMP EPC SOLENOID SYSTEM GROUND FAULT..................................................................... 723 ERROR CODE [DXH1KA]............................................................................................... 724 LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM OPEN...................................................................... 724 ERROR CODE [DXH1KB]............................................................................................... 725 LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM SHORTED................................................................... 725 ERROR CODE [DXH4KA]............................................................................................... 726 1ST_ECMV SOLENOID SYSTEM OPEN................................................................................. 726 ERROR CODE [DXH4KB]............................................................................................... 727 1ST_ECMV SOLENOID SYSTEM SHORTED.............................................................................. 727 ERROR CODE [DXH5KA]............................................................................................... 728 2ND_ECMV SOLENOID SYSTEM OPEN................................................................................. 728 ERROR CODE [DXH5KB]............................................................................................... 729 2ND_ECMV SOLENOID SYSTEM SHORTED.............................................................................. 729 ERROR CODE [DXH6KA]............................................................................................... 730 3RD_ECMV SOLENOID SYSTEM OPEN................................................................................. 730 ERROR CODE [DXH6KB]............................................................................................... 731 3RD_ECMV SOLENOID SYSTEM SHORTED.............................................................................. 731 ERROR CODE [DXH7KA]............................................................................................... 732 R_ECMV SOLENOID SYSTEM OPEN................................................................................... 732 ERROR CODE [DXH7KB]............................................................................................... 733 R_ECMV SOLENOID SYSTEM GROUND FAULT........................................................................... 733 ERROR CODE [DXH8KA]............................................................................................... 734 F_ECMV SOLENOID SYSTEM OPEN................................................................................... 734 ERROR CODE [DXH8KB]............................................................................................... 735 F_ECMV SOLENOID SYSTEM GROUND FAULT........................................................................... 735 ERROR CODE [DXHHKA]............................................................................................... 736 4TH_ECMV SOLENOID SYSTEM OPEN................................................................................. 736 ERROR CODE [DXHHKB]............................................................................................... 737 4TH_ECMV SOLENOID SYSTEM SHORTED.............................................................................. 737 ERROR CODE [DY30MA]............................................................................................... 738 MOTOR DRIVEN EMERGENCY STEERING PUMP ERROR (MALFUNCTION IN MANUAL MODE)....................................... 738 ERROR CODE [DY30MC]............................................................................................... 740 MOTOR DRIVEN EMERGENCY STEERING PUMP ERROR (MALFUNCTION IN MANUAL MODE)....................................... 740 ACTION CODE [TM-1]................................................................................................ 742 OPEN OR SHORT IN KICKDOWN SWITCH SYSTEM....................................................................... 742 ACTION CODE [TM-2]................................................................................................ 744 OPEN OR SHORT IN HOLD SWITCH (NO HOLD CONTROL PERFORMED BY PRESSING HOLD SWITCH).............................. 744 ACTION CODE [TM-3]................................................................................................ 746 TORQUE CONVERTER LOCK-UP SWITCH SYSTEM FAILURE (NO LOCK-UP PERFORMED OR NO LOCK-UP CANCELLATION PERFORMED).... 746 ACTION CODE [TM-4]................................................................................................ 748 NEUTRALIZER SIGNAL (PARKING BRAKE SWITCH SIGNAL) SYSTEM FAILURE............................................... 748 ACTION CODE [TM-5]................................................................................................ 750 EMERGENCY STEERING SWITCH (MOTOR DRIVEN EMERGENCY STEERING OPERATION SWITCH) SIGNAL SYSTEM FAILURE............ 750 ACTION CODE [TM-6]................................................................................................ 752 OPEN OR SHORT IN TRANSMISSION CUT-OFF SWITCH SYSTEM........................................................... 752 ACTION CODE [TM-7]................................................................................................ 753 OPEN OR SHORT IN TRANSMISSION CUT-OFF SETTING SWITCH SYSTEM................................................... 753 ACTION CODE [TM-8]................................................................................................ 754 TRANSMISSION CUT-OFF (LEFT BRAKE SENSOR) SIGNAL SHORTED....................................................... 754 ACTION CODE [TM-9-A].............................................................................................. 755 JOYSTICK SHIFT UP/SHIFT DOWN SWITCH SYSTEM FAILURE............................................................ 755 ACTION CODE [TM-9-B].............................................................................................. 757 FNR SWITCH MODE CHANGE OVER SWITCH SYSTEM FAILURE............................................................. 757 ACTION CODE [TM-10]............................................................................................... 759 START SWITCH “C” (IGN C) SIGNAL SYSTEM FAILURE................................................................ 759 ACTION CODE [TM-11]............................................................................................... 761 JOYSTICK ON/OFF CHANGE OVER SWITCH SYSTEM FAILURE............................................................. 761 ACTION CODE [TM-12]............................................................................................... 763 OPEN OR SHORT IN ENGINE POWER MODE SWITCH..................................................................... 763 ACTION CODE [TM-13]............................................................................................... 764 OPEN OR SHORT IN TRAVEL DAMPER ON/OFF SWITCH.................................................................. 764 ACTION CODE [TM-14]............................................................................................... 765 OPEN OR SHORT IN HYDRAULIC FAN REVERSE SWITCH SIGNAL SYSTEM................................................... 765 ACTION CODE [TM-15]............................................................................................... 767 SHORT IN MOTOR DRIVEN EMERGENCY STEERING RELAY OUTPUT SYSTEM.................................................. 767 ACTION CODE [TM-16]............................................................................................... 768 SHORT IN TRAVEL DAMPER RELAY OUTPUT SYSTEM.................................................................... 768 ACTION CODE [TM-17]............................................................................................... 769 SWITCH PUMP CUT-OFF RELAY OUTPUT SYSTEM SHORTED............................................................... 769 ACTION CODE [TM-18]............................................................................................... 770 BACK LAMP RELAY OUTPUT SYSTEM SHORTED......................................................................... 770 ACTION CODE [TM-19]............................................................................................... 771 NEUTRAL OUTPUT SYSTEM SHORTED................................................................................. 771 ACTION CODE [TM-20]............................................................................................... 773 F_ECMV SOLENOID SYSTEM SHORTED................................................................................ 773 ACTION CODE [TM-21]............................................................................................... 774 R_ECMV SOLENOID SYSTEM SHORTED................................................................................ 774 ACTION CODE [TM-22]............................................................................................... 775 1ST_ECMV SOLENOID SYSTEM SHORTED.............................................................................. 775 ACTION CODE [TM-23]............................................................................................... 776 2ND_ECMV SOLENOID SYSTEM SHORTED.............................................................................. 776 ACTION CODE [TM-24]............................................................................................... 777 3RD_ECMV SOLENOID SYSTEM SHORTED.............................................................................. 777 ACTION CODE [TM-25]............................................................................................... 778 4TH_ECMV SOLENOID SYSTEM SHORTED.............................................................................. 778 ACTION CODE [TM-26]............................................................................................... 779 LOCK-UP ECMV SOLENOID SYSTEM SHORTED.......................................................................... 779 ACTION CODE [TM-27]............................................................................................... 780 FAN PUMP EPC SOLENOID SYSTEM SHORTED.......................................................................... 780 ACTION CODE [TM-28]............................................................................................... 781 FAN REVERSE SOLENOID SYSTEM SHORTED........................................................................... 781 ACTION CODE [TM-29]............................................................................................... 782 SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM FAILURE............................................ 782 ACTION CODE [TM-30]............................................................................................... 783 TRAVEL DAMPENER SOLENOID SHORTED OR OPEN...................................................................... 783 TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (WRK MODE)........................................................ 785 CONNECTOR TYPES AND INSTALLATION POSITIONS........................................................................ 789 CONNECTOR LAYOUT DRAWING.......................................................................................... 796 WORK EQUIPMENT CONTROL SYSTEM DIAGRAM............................................................................. 802 ERROR CODE [D193KA]............................................................................................... 805 JOYSTICK STEERING CONTROL SYSTEM OPEN......................................................................... 805 ERROR CODE [D193KB]............................................................................................... 807 JOYSTICK STEERING CONTROL SYSTEM SHORTED...................................................................... 807 ERROR CODE [DB90KK]............................................................................................... 809 POWER SUPPLY TO WORK EQUIPMENT CONTROLLER IS LOW.............................................................. 809 ERROR CODE [DB92KK]............................................................................................... 811 CONTROLLER POWER TO THE SOLENOID SYSTEM IS LOW................................................................ 811 ERROR CODE [DB95KX]............................................................................................... 813 DEFECTIVE 5 VOLT POWER SUPPLY................................................................................. 813 ERROR CODE [DD1ALD]............................................................................................... 816 SHORT OR OPEN IN REMOTE POSITIONER UP SET SWITCH.............................................................. 816 ERROR CODE [DD1BLD]............................................................................................... 818 SHORT OR OPEN IN REMOTE POSITIONER “DWN” SET SWITCH........................................................... 818 ERROR CODE [DFAOKM]............................................................................................... 820 DEFECTIVE NEUTRAL CAUTION FOR JOYSTICK WORK EQUIPMENT......................................................... 820 ERROR CODE [DK59KA]............................................................................................... 822 DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER.................................................................... 822 ERROR CODE [DK59KY]............................................................................................... 824 DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER.................................................................... 824 ERROR CODE [DK59L8]............................................................................................... 826 DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER.................................................................... 826 ERROR CODE [DK5AKA]............................................................................................... 828 DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER.................................................................... 828 ERROR CODE [DK5AKY]............................................................................................... 830 DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER.................................................................... 830 ERROR CODE [DK5BKA]............................................................................................... 832 OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER............................................................... 832 ERROR CODE [DK5BKY]............................................................................................... 834 OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER............................................................... 834 ERROR CODE [DK5BL8]............................................................................................... 836 OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER............................................................... 836 ERROR CODE [DK5CKA]............................................................................................... 838 OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER............................................................... 838 ERROR CODE [DK5CKY]............................................................................................... 840 OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER............................................................... 840 ERROR CODE [DK5DKA]............................................................................................... 842 OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER............................................................... 842 ERROR CODE [DK5DKY]............................................................................................... 844 OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER............................................................... 844 ERROR CODE [DK5DL8]............................................................................................... 846 OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER............................................................... 846 ERROR CODE [DK5EKA]............................................................................................... 848 OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER............................................................... 848 ERROR CODE [DK5EKY]............................................................................................... 850 OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER............................................................... 850 ERROR CODE [DK5FKA]............................................................................................... 852 OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER............................................................. 852 ERROR CODE [DK5FKY]............................................................................................... 854 OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER............................................................. 854 ERROR CODE [DK5FKM]............................................................................................... 856 JOYSTICK STEERING EPC LEVER NEUTRAL SYSTEM.................................................................... 856 ERROR CODE [DK5FL8]............................................................................................... 857 OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER............................................................. 857 ERROR CODE [DK5GKA]............................................................................................... 859 OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER............................................................. 859 ERROR CODE [DK5GKY]............................................................................................... 861 OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER............................................................. 861 ERROR CODE [DKAOKA]............................................................................................... 863 OPEN OR SHORT IN LIFT ARM ANGLE SENSOR SYSTEM................................................................. 863 ERROR CODE [DKAOKY]............................................................................................... 865 OPEN OR SHORT IN LIFT ARM ANGLE SENSOR SYSTEM................................................................. 865 ERROR CODE [DLE2LC]............................................................................................... 867 DEFECTIVE ENGINE SPEED SENSOR SYSTEM.......................................................................... 867 ERROR CODE [DLT3LC]............................................................................................... 868 DEFECTIVE ENGINE SPEED SENSOR SYSTEM.......................................................................... 868 ERROR CODE [DUM1KB]............................................................................................... 869 REMOTE POSITIONER “RAISE” LAMP SYSTEM FAULT................................................................... 869 ERROR CODE [DUM2KB]............................................................................................... 871 REMOTE POSITIONER “LOWER” LAMP SYSTEM FAULT................................................................... 871 ERROR CODE [DW4PKA]............................................................................................... 873 OPEN IN LIFT ARM “RAISE” EPC SOLENOID SYSTEM.................................................................. 873 ERROR CODE [DW4PKB]............................................................................................... 874 SHORT IN LIFT ARM “RAISE” EPC SOLENOID SYSTEM................................................................. 874 ERROR CODE [DW4QKA]............................................................................................... 875 OPEN IN LIFT ARM “LOWER” EPC SOLENOID SYSTEM.................................................................. 875 ERROR CODE [DW4QKB]............................................................................................... 876 SHORT IN LIFT ARM “LOWER” EPC SOLENOID SYSTEM................................................................. 876 ERROR CODE [DW4RKA]............................................................................................... 877 OPEN IN BUCKET “TILT” EPC SOLENOID SYSTEM..................................................................... 877 ERROR CODE [DW4RKB]............................................................................................... 878 SHORT IN BUCKET “TILT” EPC SOLENOID SYSTEM.................................................................... 878 ERROR CODE [DW4SKA]............................................................................................... 879 OPEN IN BUCKET “DUMP” EPC SOLENOID SYSTEM..................................................................... 879 ERROR CODE [DW4SKB]............................................................................................... 880 SHORT IN BUCKET “DUMP” EPC SOLENOID SYSTEM.................................................................... 880 ERROR CODE [DWM1KA]............................................................................................... 881 OPEN IN NEUTRAL LOCK EPC SOLENOID SYSTEM...................................................................... 881 ERROR CODE [DWM1KB]............................................................................................... 882 SHORT IN neutral lock EPC SOLENOID SYSTEM..................................................................... 882 ERROR CODE [DWN6KB]............................................................................................... 883 SHORT IN LIFT ARM “RAISE” EPC LEVER DETENT.................................................................... 883 ERROR CODE [DWN6KA]............................................................................................... 885 OPEN IN LIFT ARM “RAISE” EPC LEVER DETENT..................................................................... 885 ERROR CODE [DWN7KA]............................................................................................... 887 OPEN IN LIFT ARM “FLOAT” EPC LEVER DETENT..................................................................... 887 ERROR CODE [DWN7KB]............................................................................................... 889 SHORT IN LIFT ARM “FLOAT” EPC LEVER DETENT.................................................................... 889 ERROR CODE [DWN8KA]............................................................................................... 891 OPEN OR SHORT IN BUCKET “TILT” DETENT......................................................................... 891 ERROR CODE [DWN8KB]............................................................................................... 893 OPEN OR SHORT IN BUCKET “TILT” DETENT......................................................................... 893 ERROR CODE [DXHJKA]............................................................................................... 895 OPEN IN 3RD VALVE EXTENSION EPC SOLENOID SYSTEM............................................................... 895 ERROR CODE [DXHJKB]............................................................................................... 896 SHORT IN 3RD VALVE EXTENSION EPC SOLENOID SYSTEM.............................................................. 896 ERROR CODE [DXHKKA]............................................................................................... 897 OPEN IN 3RD VALVE RETRACTION EPC SOLENOID SYSTEM.............................................................. 897 ERROR CODE [DXHKKB]............................................................................................... 898 SHORT IN 3RD VALVE RETRACTION EPC SOLENOID SYSTEM............................................................. 898 ERROR CODE [DXHLKA]............................................................................................... 899 JOYSTICK STEERING RIGHT HAND CONTROL SYSTEM OPEN.............................................................. 899 ERROR CODE [DXHLKB]............................................................................................... 901 JOYSTICK STEERING RIGHT HAND CONTROL SYSTEM SHORTED........................................................... 901 ERROR CODE [DXHMKA]............................................................................................... 903 JOYSTICK STEERING LEFT HAND CONTROL SYSTEM OPEN............................................................... 903 ERROR CODE [DXHMKB]............................................................................................... 905 JOYSTICK STEERING LEFT HAND CONTROL SYSTEM SHORTED............................................................ 905 WRK-1............................................................................................................. 907 DEFECTIVE LIFT ARM LOCK SWITCH SYSTEM......................................................................... 907 WRK-2............................................................................................................. 908 DEFECTIVE REMOTE POSITIONER “RAISE” SWITCH.................................................................... 908 WRK-3............................................................................................................. 910 DEFECTIVE REMOTE POSITIONER “LOWER” SWITCH.................................................................... 910 WRK-4............................................................................................................. 912 DEFECTIVE REMOTE POSITIONER “RAISE” SWITCH.................................................................... 912 WRK-5............................................................................................................. 914 DEFECTIVE REMOTE POSITIONER “LOWER ON-OFF” SWITCH............................................................. 914 WRK-6............................................................................................................. 916 DEFECTIVE BUCKET CYLINDER PROXIMITY SWITCH SYSTEM............................................................. 916 WRK-7............................................................................................................. 918 OPEN OR SHORT IN BUCKET CYLINDER FULL STROKE SYSTEM........................................................... 918 WRK-8............................................................................................................. 920 DEFECTIVE SEMI-AUTOMATIC DIGGING SELECTION SWITCH............................................................. 920 WRK-9............................................................................................................. 922 DEFECTIVE SEMI-AUTOMATIC DIGGING SELECTION SWITCH............................................................. 922 WRK-10............................................................................................................ 924 DEFECTIVE JOYSTICK ON/OFF SWITCH.............................................................................. 924 WRK-11............................................................................................................ 926 DEFECTIVE JOYSTICK HI/LO SWITCH............................................................................... 926 WRK-12............................................................................................................ 928 JOYSTICK STEERING LEFT HAND CONTROL SYSTEM SHORTED............................................................ 928 WRK-13............................................................................................................ 930 OPEN OR SHORT IN LIFT ARM “RAISE” EPC LEVER DETENT............................................................ 930 WRK-14............................................................................................................ 932 OPEN IN LIFT ARM “FLOAT” EPC LEVER DETENT..................................................................... 932 WRK-15............................................................................................................ 934 OPEN OR SHORT IN BUCKET “TILT” DETENT......................................................................... 934 WRK-16............................................................................................................ 935 SHORT IN NEUTRAL LOCK EPC SOLENOID SYSTEM..................................................................... 935 WRK-17............................................................................................................ 936 SHORT IN LIFT ARM “RAISE” EPC SOLENOID SYSTEM................................................................. 936 WRK-18............................................................................................................ 937 SHORT IN LIFT ARM “LOWER” EPC SOLENOID SYSTEM................................................................. 937 WRK-19............................................................................................................ 938 SHORT IN BUCKET “TILT” EPC SOLENOID SYSTEM.................................................................... 938 WRK-20............................................................................................................ 939 SHORT IN BUCKET “DUMP” EPC SOLENOID SYSTEM.................................................................... 939 WRK-21............................................................................................................ 940 SHORT IN 3RD VALVE EXTENSION EPC SOLENOID SYSTEM.............................................................. 940 WRK-22............................................................................................................ 941 SHORT IN 3RD VALVE RETRACTION EPC SOLENOID SYSTEM............................................................. 941 WRK-23............................................................................................................ 942 OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER............................................................. 942 WRK-24............................................................................................................ 944 OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER............................................................. 944 WRK-25............................................................................................................ 946 DEFECTIVE BUCKET POSITIONER LIFT ARM KICK-OUT FUNCTION........................................................ 946 WRK-26............................................................................................................ 949 DEFECTIVE BUCKET POSITIONER LIFT ARM KICK-OUT FUNCTION........................................................ 949 WRK-27............................................................................................................ 952 DEFECTIVE BUCKET LEVER FUNCTION............................................................................... 952 WRK-28............................................................................................................ 955 DEFECTIVE LIFT ARM FLOAT FUNCTION............................................................................. 955 TROUBLESHOOTING MACHINE MONITOR PANEL SYSTEM (MON MODE)............................................................... 959 CONNECTOR TYPES AND INSTALLATION LOCATIONS........................................................................ 963 CONNECTOR LAYOUT DRAWING.......................................................................................... 970 MONITOR SYSTEM DIAGRAM............................................................................................ 976 ERROR CODE [2F00KM]............................................................................................... 980 DRAGGING PARKING BRAKE........................................................................................ 980 ERROR CODE [2G42ZG]............................................................................................... 982 ACCUMULATOR OIL PRESSURE (FRONT CIRCUIT) LOW.................................................................. 982 ERROR CODE [2G43ZG]............................................................................................... 984 ACCUMULATOR OIL PRESSURE (REAR BRAKE CIRCUIT) LOW............................................................. 984 ERROR CODE [AA1ANX]............................................................................................... 986 AIR CLEANER 1 CLOGGED......................................................................................... 986 ERROR CODE [AB00L6]............................................................................................... 988 DEFECTIVE BATTERY CHARGING CIRCUIT (ALTERNATOR TERMINAL R SIGNAL DETECTED WHEN ENGINE STOPPED)................ 988 ERROR CODE [AB00MA]............................................................................................... 990 DEFECTIVE BATTERY CHARGING CIRCUIT (NO ALTERNATOR TERMINAL R SIGNAL DETECTED, DETECTION FAILURE).............. 990 ERROR CODE [B@BAZG]............................................................................................... 992 ENGINE OIL PRESSURE LOW....................................................................................... 992 ERROR CODE [B@BAZK]............................................................................................... 994 ENGINE OIL LEVEL LOW.......................................................................................... 994 ERROR CODE [B@BCZK]............................................................................................... 996 ALARM INDICATING LOW COOLANT LEVEL............................................................................ 996 ERROR CODE [B@BCNS]............................................................................................... 998 ENGINE COOLANT TEMPERATURE OVERHEATING........................................................................ 998 ERROR CODE [B@HANS]...............................................................................................1000 HYDRAULIC OIL TEMPERATURE OVERHEATING.........................................................................1000 ERROR CODE [B@CENS]...............................................................................................1002 TORQUE CONVERTER OIL TEMPERATURE OVERHEATING..................................................................1002 ERROR CODE [D5ZHL6]...............................................................................................1004 START SWITCH C (IGN "C") INPUT FAILURE........................................................................1004 ERROR CODE [DAF3KK]...............................................................................................1006 SW POWER SUPPLY (FOR OPERATION) = ON AND NSW POWER SUPPLY (FOR MEMORY) = OFF..................................1006 ERROR CODE [DAF5KP]...............................................................................................1008 5-V POWER SUPPLY OUTPUT FAILURE...............................................................................1008 ERROR CODE [DAF6KP]...............................................................................................1010 24-V POWER SUPPLY OUTPUT FAILURE..............................................................................1010 ERROR CODE [DAFBKM]...............................................................................................1012 WRONG INFORMATION ON MODEL SELECTION..........................................................................1012 ERROR CODE [DAFSKQ]...............................................................................................1013 WRONG INFORMATION ON METER DISPLAY SELECTION..................................................................1013 ERROR CODE [DAQSKR]...............................................................................................1014 S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND TRANSMISSION CONTROLLER)...............................1014 ERROR CODE [DB2SKR]...............................................................................................1016 S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND ENGINE CONTROLLER......................................1016 ERROR CODE [DA80L4]...............................................................................................1018 AUTO GREASE INPUT FAILURE.....................................................................................1018 ERROR CODE [DBQSKR]...............................................................................................1020 S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER..............................1020 ERROR CODE [DD15LD]...............................................................................................1022 MONITOR PANEL MODE SELECTOR SWITCH 1 (PANEL SW1) INPUT ERROR..................................................1022 ERROR CODE [DD16LD]...............................................................................................1024 MONITOR PANEL MODE SELECTOR SWITCH 1 (PANEL SW2) INPUT ERROR..................................................1024 ERROR CODE [DD17LD]...............................................................................................1026 MONITOR PANEL MODE SELECTOR SWITCH 2 (PANEL SW3) INPUT ERROR..................................................1026 ERROR CODE [DD18LD]...............................................................................................1028 MONITOR PANEL MODE SELECTOR SWITCH 2 (PANEL SW4) INPUT ERROR..................................................1028 ERROR CODE [DD1CLD]...............................................................................................1030 SUB-TOTAL SWITCH FAILURE......................................................................................1030 ERROR CODE [DGE2KX]...............................................................................................1032 ENGINE COOLANT TEMPERATURE SENSOR SYSTEM FAILURE..............................................................1032 ERROR CODE [DDK6KM]...............................................................................................1034 CAUTION: FNR (FORWARD-REVERSE) LEVER SWITCH IS IN N (NEUTRAL).................................................1034 ERROR CODE [DDS5L6]...............................................................................................1035 DECREASED STEERING OIL PRESSURE...............................................................................1035 ERROR CODE [DDY0LD]...............................................................................................1037 CANCEL SWITCH FAILURE.........................................................................................1037 ERROR CODE [DGH2KX]...............................................................................................1039 HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM FAILURE...............................................................1039 ERROR CODE [DGT1KX]...............................................................................................1041 TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM FAILURE........................................................1041 ERROR CODE [DHE4L6]...............................................................................................1043 ENGINE OIL PRESSURE SENSOR SYSTEM FAILURE.....................................................................1043 ERROR CODE [DHPCKX]...............................................................................................1045 BOTTOM PRESSURE SENSOR FAILURE................................................................................1045 ERROR CODE [DHPDKX]...............................................................................................1047 HEAD PRESSURE SENSOR FAILURE..................................................................................1047 ERROR CODE [DKA0KX]...............................................................................................1049 BOOM ANGLE SENSOR FAILURE.....................................................................................1049 ERROR CODE [DV00KB]...............................................................................................1051 SHORT-CIRCUITED ALARM BUZZER OUTPUT SYSTEM....................................................................1051 ERROR CODE [DY30ME]...............................................................................................1053 THE EMERGENCY STEERING REMAINS ACTUATED FOR MORE THAN ONE MINUTE..............................................1053 ACTION CODE [MON-1]...............................................................................................1055 THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT UP WHEN THE PARKING BRAKE SWITCH IS TURNED ON.................1055 ACTION CODE [MON-2]...............................................................................................1057 CIRCUIT DIAGNOSTIC PROCEDURES FOR ERROR CODE..................................................................1057 ACTION CODE [MON-3]...............................................................................................1059 THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (REAR C.............1059 ACTION CODE [MON-4]...............................................................................................1061 THE AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT ON.....................................................1061 ACTION CODE [MON-5]...............................................................................................1063 THE ENGINE HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON...........................................................1063 ACTION CODE [MON-6]...............................................................................................1065 THE ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT ON...........................................................1065 ACTION CODE [MON-7]...............................................................................................1067 THE ENGINE COOLANT TEMPERATURE CAUTION LAMP DOES NOT LIGHT....................................................1067 ACTION CODE [MON-8]...............................................................................................1069 THE RADIATOR COOLANT VOLUME CAUTION LAMP DOES NOT LIGHT ON....................................................1069 ACTION CODE [MON-9]...............................................................................................1071 THE HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT.....................................................1071 ACTION CODE [MON-10]..............................................................................................1073 THE TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON...........................................1073 ACTION CODE [MON-11]..............................................................................................1075 THE STEERING HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON.........................................................1075 ACTION CODE [MON-12]..............................................................................................1077 INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW1)........................................................1077 ACTION CODE [MON-13]..............................................................................................1079 INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW2)........................................................1079 ACTION CODE [MON-14]..............................................................................................1081 INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW3)........................................................1081 ACTION CODE [MON-15]..............................................................................................1083 INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW4)........................................................1083 ACTION CODE [MON-16]..............................................................................................1085 DEFECTIVE SUBTOTAL SWITCH.....................................................................................1085 ACTION CODE [MON-17]..............................................................................................1087 DEFECTIVE CANCEL SWITCH.......................................................................................1087 ACTION CODE [MON-18]..............................................................................................1089 DEFECTIVE BOTTOM PRESSURE SENSOR (SHORT FAULT)................................................................1089 ACTION CODE [MON-19]..............................................................................................1091 DEFECTIVE HEAD SENSOR.........................................................................................1091 ACTION CODE [MON-20]..............................................................................................1093 THE ALARM BUZZER DOES NOT SOUND OR STOP.......................................................................1093 TROUBLESHOOTING OF CHASSIS ELECTRICAL SYSTEM (E MODE).................................................................1095 CONNECTOR TYPES AND INSTALLATION LOCATIONS........................................................................1096 CONNECTOR LAYOUT DRAWING..........................................................................................1103 ELECTRICAL SYSTEM DIAGRAM.........................................................................................1109 ACTION CODE: [E-1]................................................................................................1111 BUCKET POSITIONER, BOOM KICK-OUT, AND FLOAT DO NOT FUNCTION...................................................1111 ACTION CODE [E-2].................................................................................................1113 BOOM KICK-OUT DOES NOT FUNCTION OR CANNOT BE RELEASED.........................................................1113 ACTION CODE: [E-3]................................................................................................1115 BUCKET LEVER DOES NOT FUNCTION OR CANNOT BE RELEASED..........................................................1115 ACTION CODE: [E-4]................................................................................................1117 BOOM FLOAT DOES NOT FUNCTION OR CANNOT BE CANCLED.............................................................1117 ACTION CODE: [E-5A]...............................................................................................1119 THE FRONT WIPER DOES NOT FUNCTION.............................................................................1119 ACTION CODE: [E-5B]...............................................................................................1122 THE REAR WIPER DOES NOT FUNCTION..............................................................................1122 ACTION CODE: [E-5C]...............................................................................................1124 THE SIDE WIPER DOES NOT FUNCTION..............................................................................1124 ACTION CODE: [E-6]................................................................................................1126 THE WINDOW WASHER DOES NOT FUNCTION...........................................................................1126 ACTION CODE: [E-7A]...............................................................................................1128 THE HEADLAMP (LO BEAM) DOES NOT FUNCTION......................................................................1128 ACTION CODE: [E-7B]...............................................................................................1130 THE HEADLAMP (HI BEAM) DOES NOT FUNCTION......................................................................1130 ACTION CODE: [E-7C]...............................................................................................1132 CLEARANCE LAMPS DO NOT FUNCTION...............................................................................1132 ACTION CODE: [E-7D]...............................................................................................1134 TURN SIGNAL DOES NOT FUNCTION.................................................................................1134 ACTION CODE: [E-8]................................................................................................1137 HORN DOES NOT SOUND...........................................................................................1137 CODE: [E-9].......................................................................................................1138 AIR CONDITIONER SYSTEM DOES NOT WORK..........................................................................1138 CODE: (E-9).......................................................................................................1141 AIR DOES NOT FLOW FROM SYSTEM AND CANNOT BE ADJUSTED..........................................................1141 30 DISASSEMBLY AND ASSEMBLY...............................................................................................1145 METHOD OF USING MANUAL................................................................................................1149 PRECAUTIONS WHEN CARRYING OUT OPERATION...............................................................................1150 FUEL SUPPLY PUMP ASSEMBLY.............................................................................................1153 SPECIAL TOOLS.....................................................................................................1153 REMOVAL...........................................................................................................1153 INSTALLATION......................................................................................................1156 SCHEMATIC DRAWINGS OF SPECIAL TOOLS...............................................................................1159 A1 Remover....................................................................................................1159 A1 Block......................................................................................................1159 A1 Bolt.......................................................................................................1160 NOZZLE HOLDER ASSEMBLY................................................................................................1161 REMOVAL...........................................................................................................1161 INSTALLATION......................................................................................................1164 CYLINDER HEAD ASSEMBLY................................................................................................1166 SPECIAL TOOL......................................................................................................1166 REMOVAL...........................................................................................................1166 INSTALLATION......................................................................................................1173 RADIATOR ASSEMBLY.....................................................................................................1176 REMOVAL...........................................................................................................1176 INSTALLATION......................................................................................................1178 AIR AFTERCOOLER ASSEMBLY..............................................................................................1179 REMOVAL...........................................................................................................1179 INSTALLATION......................................................................................................1179 COOLING FAN DRIVE MOTOR...............................................................................................1180 REMOVAL...........................................................................................................1180 INSTALLATION......................................................................................................1181 ENGINE ASSEMBLY.......................................................................................................1182 REMOVAL...........................................................................................................1182 INSTALLATION......................................................................................................1188 STEERING, SWITCH, COOLING FAN PUMPS...................................................................................1190 REMOVAL...........................................................................................................1190 INSTALLATION......................................................................................................1191 TORQUE CONVERTER CHARGE, WORK EQUIPMENT AND PPC PUMP ASSEMBLY.........................................................1192 REMOVAL...........................................................................................................1192 INSTALLATION......................................................................................................1192 TORQUE CONVERTER, TRANSMISSION ASSEMBLY...............................................................................1193 REMOVAL...........................................................................................................1193 INSTALLATION......................................................................................................1198 TORQUE CONVERTER ASSEMBLY (standard)..................................................................................1199 SPECIAL TOOLS.....................................................................................................1199 DISASSEMBLY.......................................................................................................1199 ASSEMBLY..........................................................................................................1201 TORQUE CONVERTER ASSEMBLY (lock-up)...................................................................................1204 SPECIAL TOOLS.....................................................................................................1204 DISASSEMBLY.......................................................................................................1204 ASSEMBLY..........................................................................................................1207 TRANSMISSION ASSEMBLY.................................................................................................1212 SPECIAL TOOLS.....................................................................................................1212 DISASSEMBLY.......................................................................................................1212 ASSEMBLY..........................................................................................................1220 SCHEMATICS OF SPECIAL TOOLS.......................................................................................1230 C1 Bracket....................................................................................................1230 C6, C7 Pushing tools..........................................................................................1230 C7 Spacer.....................................................................................................1231 C11 Lifting tool..............................................................................................1231 C11 Lifting tool..............................................................................................1232 TRANSMISSION CLUTCH PACK ASSEMBLY.....................................................................................1233 SPECIAL TOOLS.....................................................................................................1233 DISASSEMBLY.......................................................................................................1233 Disassembly of forward-reverse clutch packs...................................................................1233 Forward clutch................................................................................................1233 Reverse clutch................................................................................................1235 Disassembly of 1st • 4th speed clutch packs...................................................................1236 1st speed clutch..............................................................................................1236 4th speed clutch..............................................................................................1237 Disassembly of 2nd • 3rd clutch packs.........................................................................1238 3rd clutch....................................................................................................1238 2nd speed clutch..............................................................................................1240 Assembly of forward-reverse clutch packs......................................................................1241 Reverse clutch................................................................................................1241 Forward clutch................................................................................................1243 Assembly of 1st • 4th clutch packs............................................................................1245 4th-speed clutch..............................................................................................1245 1st-speed clutch..............................................................................................1247 Assembly of 2nd • 3rd clutch packs............................................................................1249 2nd-speed clutch..............................................................................................1249 3rd-speed clutch..............................................................................................1251 SCHEMATIC DIAGRAM OF SPECIAL TOOL.................................................................................1255 C2 Push tool..................................................................................................1255 PARKING BRAKE ASSEMBLY................................................................................................1256 SPECIAL TOOLS.....................................................................................................1256 DISASSEMBLY.......................................................................................................1256 ASSEMBLY..........................................................................................................1259 SCHEMATIC DRAWING OF SPECIAL TOOLS................................................................................1265 C4, C5 Push tool..............................................................................................1265 C5 Spacer.....................................................................................................1265 C8 Push tool..................................................................................................1266 C9 Push tool..................................................................................................1266 C10 Push tool.................................................................................................1267 C13 Bracket...................................................................................................1267 FRONT AXLE ASSEMBLY...................................................................................................1268 DISASSEMBLY.......................................................................................................1268 ASSEMBLY..........................................................................................................1270 REAR AXLE ASSEMBLY....................................................................................................1271 REMOVAL...........................................................................................................1271 INSTALLATION......................................................................................................1274 AXLE HOUSING ASSEMBLY.................................................................................................1276 SPECIAL TOOLS.....................................................................................................1276 DISASSEMBLY.......................................................................................................1276 ASSEMBLY..........................................................................................................1280 SCHEMATIC DRAWING OF SPECIAL TOOLS................................................................................1286 D7 Pushing tool...............................................................................................1286 D7 Spacer.....................................................................................................1286 D7 Pushing tool...............................................................................................1287 D9 Support....................................................................................................1287 D9 Support....................................................................................................1288 DIFFERENTIAL ASSEMBLY.................................................................................................1289 SPECIAL TOOLS.....................................................................................................1289 DISASSEMBLY.......................................................................................................1289 ASSEMBLY..........................................................................................................1295 SCHEMATIC DRAWING OF SPECIAL TOOLS................................................................................1307 D1 Plate......................................................................................................1307 D2, D3 Push tool..............................................................................................1307 D3 Spacer.....................................................................................................1308 D4 Push tool..................................................................................................1308 D5 Push tool..................................................................................................1309 CENTER HINGE PIN......................................................................................................1310 SPECIAL TOOLS.....................................................................................................1310 REMOVAL...........................................................................................................1310 INSTALLATION......................................................................................................1316 VALVE ASSEMBLY........................................................................................................1320 REMOVAL...........................................................................................................1320 INSTALLATION......................................................................................................1320 TRAVEL DAMPER ASSEMBLY................................................................................................1321 REMOVAL...........................................................................................................1321 INSTALLATION......................................................................................................1321 PARKING BRAKE DISC....................................................................................................1322 SPECIAL TOOLS.....................................................................................................1322 REMOVAL...........................................................................................................1322 INSTALLATION......................................................................................................1324 SCHEMATIC DRAWING OF SPECIAL TOOLS................................................................................1325 C13 Bracket...................................................................................................1325 HYDRAULIC TANK........................................................................................................1326 REMOVAL...........................................................................................................1326 INSTALLATION......................................................................................................1327 WORK EQUIPMENT VALVE ASSEMBLY.........................................................................................1328 REMOVAL...........................................................................................................1328 INSTALLATION......................................................................................................1329 HYDRAULIC CYLINDER ASSEMBLY...........................................................................................1330 SPECIAL TOOLS.....................................................................................................1330 DISASSEMBLY.......................................................................................................1330 ASSEMBLY..........................................................................................................1334 WORK EQUIPMENT ASSEMBLY...............................................................................................1340 REMOVAL...........................................................................................................1340 INSTALLATION......................................................................................................1343 COUNTERWEIGHT.........................................................................................................1345 REMOVAL...........................................................................................................1345 INSTALLATION......................................................................................................1346 FUEL TANK ASSEMBLY....................................................................................................1347 REMOVAL...........................................................................................................1347 INSTALLATION......................................................................................................1348 CAB ASSEMBLY..........................................................................................................1349 REMOVAL...........................................................................................................1349 INSTALLATION......................................................................................................1352 CAB, FLOOR FRAME ASSEMBLY.............................................................................................1353 REMOVAL...........................................................................................................1353 INSTALLATION......................................................................................................1357 AIR CONDITIONER UNIT ASSEMBLY.........................................................................................1358 REMOVAL...........................................................................................................1358 INSTALLATION......................................................................................................1361 AIR CONDITIONER COMPRESSOR ASSEMBLY...................................................................................1362 SPECIAL TOOLS.....................................................................................................1362 REMOVAL...........................................................................................................1362 INSTALLATION......................................................................................................1363 90 OTHERS................................................................................................................. 0 BRAKE OIL CIRCUIT DIAGRAM............................................................................................. 0 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN............................................................................. 0 WITHOUT TORQUE CONVETER LOCKUP CLUTCH............................................................................ 0 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN............................................................................. 0 WITH TORQUE CONVERTER LOCKUP CLUTCH............................................................................... 0 HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT.......................................................................... 0 STANDARD.......................................................................................................... 0 ELECTRIC CIRCUIT DIAGRAM.............................................................................................. 0 FLOOR HARNESS......................................................................................................... 0 STANDARD.......................................................................................................... 0 FOR JOYSTICK...................................................................................................... 0 ENGINE HARNESS.................................................................................................... 0 ECSS AND LOAD METER SUPPLEMENT............................................................................................1380 COVER.................................................................................................................1380 CONTENTS..............................................................................................................1381 ECSS VALVE (OP).......................................................................................................1382 MACHINE MONITOR.......................................................................................................1384 LOAD METER FUNCTION (OP)..........................................................................................1384 AMP070-20 [CN-L51]................................................................................................1393 AMP070-12P [CN-L57]...............................................................................................1395 TRANSMISSION CONTROLLER...............................................................................................1397 INPUT AND OUTPUT SIGNALS..........................................................................................1398 TESTING AND ADJUSTING LOAD METER......................................................................................1399 TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM......................................................................1403 CONNECTOR TYPES AND INSTALLATION POSITIONS........................................................................1403 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)..............................................................1411 H-30 ECSS DOES NOT WORK, AND THERE IS PITCHING AND BOUNCING.......................................................1411
KOMATSU WA450-5L, WA480-5L GALEO WHEEL LOADER SHOP MANUAL A36001 AND UP, A37001 AND UP – DOWNLOAD:
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