Komatsu WA400-5 70001 and up Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA400-5 70001 and up Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA400-5
Serial Number: 70001 and up
Book Code: SEBM028006
Language: English
Pages: 1167
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA400-5 70001 and up Wheel Loader Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu WA400-5 70001 and up Wheel Loader Shop Manual
COVER................................................................................................................................................................................................ 1 CONTENTS............................................................................................................................................................................................. 2 01 GENERAL........................................................................................................................................................................................... 28 GENERAL ASSEMBLY DRAWING......................................................................................................................................................................... 29 SPECIFICATIONS................................................................................................................................................................................... 30 WEIGHT TABLE..................................................................................................................................................................................... 34 LIST OF LUBRICANT AND COOLANT.................................................................................................................................................................... 36 10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD...................................................................................................................................................... 38 COOLING SYSTEM................................................................................................................................................................................... 39 ENGINE MOUNT, TRANSMISSION MOUNT................................................................................................................................................................. 40 POWER TRAIN...................................................................................................................................................................................... 41 POWER TRAIN SYSTEM DIAGRAM....................................................................................................................................................................... 42 DRIVE SHAFT (PROPELLER SHAFT).................................................................................................................................................................... 45 TORQUE CONVERTER,TRANSMISSION PIPING............................................................................................................................................................. 46 TORQUE CONVERTER................................................................................................................................................................................. 47 TRANSMISSION..................................................................................................................................................................................... 55 TRANSMISSION CONTROL VALVE....................................................................................................................................................................... 70 AXLE............................................................................................................................................................................................. 85 DIFFERENTIAL..................................................................................................................................................................................... 87 FINAL DRIVE...................................................................................................................................................................................... 98 AXLE MOUNTING,CENTER HINGE PIN................................................................................................................................................................... 104 STEERING PIPING.................................................................................................................................................................................. 108 STEERING COLUMN, ORBIT-ROLL...................................................................................................................................................................... 109 STEERING VALVE................................................................................................................................................................................... 110 ORBIT-ROLL VALVE................................................................................................................................................................................. 125 STOP VALVE....................................................................................................................................................................................... 129 STEERING PUMP, SWITCH PUMP....................................................................................................................................................................... 130 EMERGENCY STEERING PUMP (OP)..................................................................................................................................................................... 132 EMERGENCY STEERING MOTOR (OP).................................................................................................................................................................... 133 STEERING CYLINDER................................................................................................................................................................................ 134 JOYSTICK STEERING LEVER (OP)..................................................................................................................................................................... 136 STEERING LEVER (OP).............................................................................................................................................................................. 137 STEERING SWITCH VALVE (OP)....................................................................................................................................................................... 139 BRAKE PIPING..................................................................................................................................................................................... 140 BRAKE VALVE...................................................................................................................................................................................... 142 CHARGE VALVE..................................................................................................................................................................................... 149 ACCUMULATOR (FOR BRAKE).......................................................................................................................................................................... 153 BRAKE............................................................................................................................................................................................ 155 PARKING BRAKE CONTROL............................................................................................................................................................................ 160 PARKING BRAKE.................................................................................................................................................................................... 161 PARKING BRAKE SOLENOID VALVE..................................................................................................................................................................... 163 PARKING BRAKE EMERGENCY RELEASE VALVE............................................................................................................................................................ 165 HYDRAULIC PIPING................................................................................................................................................................................. 166 WORK EQUIPMENT CONTROL LEVER..................................................................................................................................................................... 169 HYDRAULIC TANK................................................................................................................................................................................... 171 TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PILOT CONTROL PUMPS............................................................................................................................... 173 PPC RELIEF VALVE................................................................................................................................................................................. 175 ECSS VALVE....................................................................................................................................................................................... 177 WORK EQUIPMENT CONTROL VALVE..................................................................................................................................................................... 179 WORK EQUIPMENT PPC VALVE......................................................................................................................................................................... 196 PPC VALVE (FOR MULTI FUNCTION MONO LEVER)........................................................................................................................................................ 202 EPC SOLENOID VALVE (OP).......................................................................................................................................................................... 208 SHUT OFF VALVE (OP).............................................................................................................................................................................. 211 ATTACHMENT PPC VALVE (OP)........................................................................................................................................................................ 212 COOLING FAN MOTOR................................................................................................................................................................................ 216 COOLING FAN MOTOR DRIVE PUMP..................................................................................................................................................................... 221 WORK EQUIPMENT LINKAGE........................................................................................................................................................................... 229 BUCKET........................................................................................................................................................................................... 231 BUCKET POSITIONER, LIFT ARM KICK-OUT............................................................................................................................................................. 232 WORK EQUIPMENT CYLINDER.......................................................................................................................................................................... 238 CAB.............................................................................................................................................................................................. 239 AIR CONDITIONER (OP)............................................................................................................................................................................. 240 MACHINE MONITORING SYSTEM........................................................................................................................................................................ 241 MACHINE MONITOR.................................................................................................................................................................................. 248 TRANSMISSION CONTROL SYSTEM...................................................................................................................................................................... 307 TRANSMISSION CONTROLLER.......................................................................................................................................................................... 333 JOY STICK STEERING CONTROL SYSTEM (OP)........................................................................................................................................................... 335 WORK EQUIPMENT CONTROLLER........................................................................................................................................................................ 341 ELECTRIC TRANSMISSION CONTROL.................................................................................................................................................................... 343 KICK DOWN, HOLD SWITCH........................................................................................................................................................................... 347 ENGINE STARTING CIRCUIT.......................................................................................................................................................................... 348 ENGINE STOP CIRCUIT.............................................................................................................................................................................. 350 PREHEATING CIRCUIT............................................................................................................................................................................... 351 ENGINE POWER MODE SELECTOR CIRCUIT............................................................................................................................................................... 352 PARKING BRAKE CIRCUIT............................................................................................................................................................................ 353 SENSORS.......................................................................................................................................................................................... 357 20 TESTING AND ADJUSTING............................................................................................................................................................................. 367 STANDARD VALUE TABLE FOR ENGINE.................................................................................................................................................................. 368 STANDARD VALUE TABLE FOR CHASSIS................................................................................................................................................................. 369 TESTING AND SDJUSTING............................................................................................................................................................................ 376 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING............................................................................................................................................ 377 MEASURING ENGINE SPEED....................................................................................................................................................................... 378 MEASURING EXHAUST COLOR...................................................................................................................................................................... 380 MEASURING EXHAUST TEMPERATURE................................................................................................................................................................ 381 ADJUSTING VALVE CLEARANCE.................................................................................................................................................................... 382 MEASURING COMPRESSION PRESSURE............................................................................................................................................................... 384 MEASURING BLOW-BY PRESSURE................................................................................................................................................................... 385 MEASURING ENGINE OIL PRESSURE................................................................................................................................................................ 386 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)............................................................................................................................................... 387 TESTING AND ADJUSTING FUEL INJECTION TIMING.................................................................................................................................................. 388 ADJUSTING ENGINE SPEED SENSOR................................................................................................................................................................ 389 BLEEDING AIR FROM FUEL CIRCUIT............................................................................................................................................................... 390 ADJUSTING ENGINE STOP SOLENOID............................................................................................................................................................... 391 ADJUSTING ACCELERATOR PEDAL.................................................................................................................................................................. 392 ADJUSTING TRANSMISSION SPEED SENSOR.......................................................................................................................................................... 394 TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE............................................................................................................................................... 395 DRAWING OF SPECIAL TOOL...................................................................................................................................................................... 399 PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT...................................................................................................................... 400 PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS................................................................................................................................... 401 TESTING AND ADJUSTING STEERING CONTROL....................................................................................................................................................... 403 TESTING AND ADJUSTING STEERING OIL PRESSURE.................................................................................................................................................. 404 TESTING HYDRAULIC FAN........................................................................................................................................................................ 406 MEASURING BRAKE OIL PRESSURE................................................................................................................................................................. 407 TESTING WEAR OF WHEEL BRAKE DISC............................................................................................................................................................. 409 BLEEDING AIR FROM BRAKE CIRCUIT.............................................................................................................................................................. 410 TESTING WEAR OF PARKING BRAKE DISC........................................................................................................................................................... 411 MANUAL RELEASE METHOD FOR PARKING BRAKE...................................................................................................................................................... 412 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE............................................................................................................................................ 413 TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE..................................................................................................................................... 415 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE...................................................................................................................................... 417 TESTING AND ADJUSTING BUCKET POSITIONER...................................................................................................................................................... 419 TESTING AND ADJUSTING LIFT ARM KICK-OUT...................................................................................................................................................... 420 CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP............................................................................................................................................... 421 ADJUSTING MACHINE MONITOR.................................................................................................................................................................... 422 TESTING AND ADJUSTING LOAD METER............................................................................................................................................................. 425 BLEEDING AIR................................................................................................................................................................................. 429 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT............................................................................................................................................ 430 RELEASING REMAINING PRESSURE IN TRAVEL DAMPER CIRCUIT........................................................................................................................................ 430 PM CLINIC INSPECTION TABLE................................................................................................................................................................... 431 TROUBLESHOOTING.................................................................................................................................................................................. 433 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................................................................... 434 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................................................................................ 435 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.................................................................................................................................................... 436 CHECKS BEFORE TROUBLESHOOTING................................................................................................................................................................ 444 EQUIPMENT FOR TROUBLESHOOTING ELECTRICAL SYSTEM.............................................................................................................................................. 445 SPECIAL FUNCTIONS OF MACHINE MONITOR......................................................................................................................................................... 446 CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................................................ 477 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................................................................................................... 485 T-ADAPTER TABLE.............................................................................................................................................................................. 507 TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (TM MODE)..................................................................................................................................... 510 CONNECTOR TYPES AND MOUNTING LOCATIONS................................................................................................................................................... 512 CONNECTOR LAYOUT DRAWING................................................................................................................................................................. 520 TRANSMISSION CONTROL SYSTEM DIAGRAM...................................................................................................................................................... 526 ERROR CODE [1500L1] (DOUBLE ENGAGEMENT DETECTED) IS DISPLAYED............................................................................................................................ 529 ERROR CODE [15SAL1] (F_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED............................................................................................................. 530 ERROR CODE [15SALH] (F_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED................................................................................................................ 531 ERROR CODE [15SBL1] (R_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED............................................................................................................. 532 ERROR CODE [15SBLH] (R_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED................................................................................................................ 533 ERROR CODE [15SEL1] (1ST_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED........................................................................................................... 534 ERROR CODE [15SELH] (1ST_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED.............................................................................................................. 535 ERROR CODE [15SFL1] (2ND_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED........................................................................................................... 536 ERROR CODE [15SFLH] (2ND_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED.............................................................................................................. 537 ERROR CODE [15SGL1] (3RD_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED........................................................................................................... 538 ERROR CODE [15SGLH] (3RD_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED.............................................................................................................. 539 ERROR CODE [15SHL1] (4TH_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED........................................................................................................... 540 ERROR CODE [15SHLH] (4TH_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED.............................................................................................................. 541 ERROR CODE [15SJL1] (LOCKUP_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED........................................................................................................ 542 ERROR CODE [15SJLH] (LOCKUP_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED........................................................................................................... 543 ERROR CODE [989F00] (TRANSMISSION PROTECTION CAUTION) IS DISPLAYED....................................................................................................................... 544 ERROR CODE [B@C7NS] (REAR BRAKE COOLING OIL OVERHEAT) IS DISPLAYED....................................................................................................................... 545 ERROR CODE [D150KA] (EMERGENCY STEERING RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED................................................................................................... 546 ERROR CODE [D150KB] (EMERGENCY STEERING RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED....................................................................................................... 547 ERROR CODE [D160KA] (BACKUP LAMP RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED.......................................................................................................... 548 ERROR CODE [D160KB] (BACKUP LAMP RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED.............................................................................................................. 549 ERROR CODE [D191KA] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED....................................................................................................... 550 ERROR CODE [D191KB] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED........................................................................................................... 552 ERROR CODE [D192KA] (TRAVEL DAMPER RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED........................................................................................................ 554 ERROR CODE [D192KB] (TRAVEL DAMPER RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED............................................................................................................ 555 ERROR CODE [D198KB] (GROUND FAULT IN LOW TEMPERATURE BYPASS RELAY SYSTEM)................................................................................................................ 556 ERROR CODE [D198KY] (HOT SHORT IN LOW-TEMPERATURE BYPASS RELAY SYSTEM) .................................................................................................................. 557 ERROR CODE [DAQ0KK] (CONTROLLER POWER SUPPLY VOLTAGE LOWERED) IS DISPLAYED............................................................................................................... 558 ERROR CODE [DAQ2KK] (DEFECTIVE SOLENOID POWER SUPPLY SYSTEM) IS DISPLAYED................................................................................................................ 559 ERROR CODE [DAQ9KQ] (MODEL SELECTION SIGNAL MISMATCH) IS DISPLAYED....................................................................................................................... 560 ERROR CODE [DDK3KA] (RIGHT FNR SWITCH SIGNAL NOT INPUT) IS DISPLAYED..................................................................................................................... 561 ERROR CODE [DDK3KB] (MULTIPLE RIGHT FNR SWITCH SIGNAL INPUT) IS DISPLAYED................................................................................................................ 563 ERROR CODE [DDK4KA] (JOYSTICK FORWARD/REVERSE SWITCH SIGNAL IS NOT INPUT) IS DISPLAYED................................................................................................... 565 ERROR CODE [DDK4KB] (MULTIPLE JOYSTICK FORWARD/REVERSE SWITCH SIGNALS ARE INPUT) IS DISPLAYED............................................................................................ 567 ERROR CODE [DDK5LD] (SHORT CIRCUIT WITH POWER SOURCE IN JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH) IS DISPLAYED................................................................................ 569 ERROR CODE [DDK6KA] (FORWARD-REVERSE LEVER SIGNAL NOT INPUT) IS DISPLAYED................................................................................................................ 570 ERROR CODE [DDK6KB] (MULTIPLE FORWARD-REVERSE LEVER SIGNAL INPUT) IS DISPLAYED........................................................................................................... 572 ERROR CODE [DDS5KA] (STEERING PRESSURE SWITCH DISCONNECTED) IS DISPLAYED................................................................................................................. 574 ERROR CODE [DDS5KB] (STEERING PRESSURE SWITCH GROUNDED) IS DISPLAYED..................................................................................................................... 575 ERROR CODE [DDT0L4] (MANUAL/AUTO-SHIFT SELECTOR SWITCH SELECTION FAILURE) IS DISPLAYED................................................................................................... 576 ERROR CODE [DDT4LD] (GROUND FAULT OF TRANSMISSION CUT-OFF SETTING SWITCH) IS DISPLAYED................................................................................................... 578 ERROR CODE [DDW9LD] (GROUND FAULT OF KICKDOWN SWITCH SYSTEM) IS DISPLAYED................................................................................................................ 579 ERROR CODE [DDWLLD] (GROUND FAULT OF HOLD SWITCH SYSTEM) IS DISPLAYED.................................................................................................................... 581 ERROR CODE [DF10KA] (NO INPUT OF GEAR SHIFT LEVER SIGNAL) IS DISPLAYED................................................................................................................... 582 ERROR CODE [DF10KB] (INPUT OF MULTIPLE GEAR SHIFT LEVER SIGNALS) IS DISPLAYED............................................................................................................ 584 ERROR CODE [DGF1KX] (TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM FAILURE) IS DISPLAYED.................................................................................................... 586 ERROR CODE [DGR2KA] (REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM DISCONNECTION) IS DISPLAYED................................................................................................ 587 ERROR CODE [DGR2KB] (GROUND FAULT OF REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED.............................................................................................. 588 ERROR CODE [DHT1KX] (TRANSMISSION CUT-OFF (LEFT BRAKE PRESSURE SENSOR) SIGNAL DISCONTINUITY) IS DISPLAYED................................................................................ 589 ERROR CODE [DLE2KA] (ENGINE REVOLUTION SENSOR SYSTEM DISCONTINUITY) IS DISPLAYED......................................................................................................... 590 ERROR CODE [DLE2LC] (ENGINE REVOLUTION SENSOR FAILURE) IS DISPLAYED...................................................................................................................... 591 ERROR CODE [DLT3KA] (SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM DISCONTINUITY) IS DISPLAYED.............................................................................. 592 ERROR CODE [DT20KB] (GROUND FAULT OF BUILT-IN INDICATOR LAMP SYSTEM OF TRANSMISSION CUT-OFF SWITCH) IS DISPLAYED......................................................................... 593 ERROR CODE [DW7BKA] (FAN PUMP REVERSE SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED........................................................................................................ 594 ERROR CODE [DW7BKB] (FAN PUMP REVERSE SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED..................................................................................................... 595 ERROR CODE [DW7CKA] (SWITCH PUMP CUT-OFF RELAY DISCONTINUITY) IS DISPLAYED............................................................................................................... 596 ERROR CODE [DW7CKB] (SWITCH PUMP CUT-OFF RELAY GROUND FAULT) IS DISPLAYED................................................................................................................ 597 ERROR CODE [DX16KA] (FAN PUMP EPC SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED............................................................................................................ 598 ERROR CODE [DX16KB] (FAN PUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED............................................................................................................. 599 ERROR CODE [DXH1KA] (LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED..................................................................................................... 600 ERROR CODE [DXH1KB] (LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED.................................................................................................. 601 ERROR CODE [DXH4KA] (1ST_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED................................................................................................................ 602 ERROR CODE [DXH4KB] (1ST_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED............................................................................................................. 603 ERROR CODE [DXH5KA] (2ND_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED................................................................................................................ 604 ERROR CODE [DXH5KB] (2ND_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED............................................................................................................. 605 ERROR CODE [DXH6KA] (3RD_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED................................................................................................................ 606 ERROR CODE [DXH6KB] (3RD_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED............................................................................................................. 607 ERROR CODE [DXH7KA] (R_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED.................................................................................................................. 608 ERROR CODE [DXH7KB] (R_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED................................................................................................................... 609 ERROR CODE [DXH8KA] (F_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED.................................................................................................................. 610 ERROR CODE [DXH8KB] (F_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED................................................................................................................... 611 ERROR CODE [DXHHKA] (4TH_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED................................................................................................................ 612 ERROR CODE [DXHHKB] (4TH_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED............................................................................................................. 613 ERROR CODE [DY30MA] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE)).......................................................................................... 614 ERROR CODE [DY30MC] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE)).......................................................................................... 616 ACTION CODE [TM-1] DISCONTINUITY OR HOT SHORT-CIRCUITING OF KICKDOWN SWITCH SYSTEM....................................................................................................... 618 ACTION CODE [TM-2] HOLD SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING.............................................................................................................. 620 ACTION CODE [TM-3] TORQUE CONVERTER LOCK-UP SWITCH SYSTEM FAILURE........................................................................................................................ 622 ACTION CODE [TM-4] NEUTRALIZER SIGNAL (PARKING BRAKE SWITCH SIGNAL) SYSTEM FAILURE....................................................................................................... 623 ACTION CODE [TM-5] EMERGENCY STEERING SWITCH (MOTOR-DRIVEN EMERGENCY STEERING OPERATION SWITCH) SIGNAL SYSTEM FAILURE.................................................................... 625 ACTION CODE [TM-6] TRANSMISSION CUT-OFF SWITCH SYSTEM DISCONTINUITY OR GROUND FAULT ..................................................................................................... 627 ACTION CODE [TM-7] TRANSMISSION CUT-OFF SETTING SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING...................................................................................... 628 ACTION CODE [TM-8] TRANSMISSION CUT-OFF (LEFT BRAKE SENSOR) SIGNAL SHORT-CIRCUITING...................................................................................................... 629 ACTION CODE [TM-9] JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH SYSTEM FAILURE (DISCONTINUITY OR GROUND FAULT).................................................................................... 630 ACTION CODE [TM-10-a] JOYSTICK ON/OFF CHANGE OVER SWITCH SYSTEM FAILURE.................................................................................................................. 631 ACTION CODE [TM-10-b] STARTING SWITCH "C" (IGN_C) SIGNAL SYSTEM FAILURE.................................................................................................................. 633 ACTION CODE [TM-11] FNR SWITCH MODE CHANGE OVER SWITCH SYSTEM FAILURE.................................................................................................................... 635 ACTION CODE [TM-12] ENGINE POWER MODE SWITCH DISCONTINUITY OR GROUND FAULT............................................................................................................... 636 ACTION CODE [TM-13] TRAVEL DAMPER NO/OFF SWITCH DISCONTINUITY OR GROUND FAULT............................................................................................................ 637 ACTION CODE [TM-14] HYDRAULIC FAN REVERSE SWITCH SIGNAL SYSTEM HOT SHORT-CIRCUITING OR DISCONTINUITY..................................................................................... 638 ACTION CODE [TM-15] MOTOR-DRIVEN EMERGENCY STEERING RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING............................................................................................. 639 ACTION CODE [TM-16] TRAVEL DAMPER RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING .............................................................................................................. 640 ACTION CODE [TM-17] SWITCH PUMP CUT-OFF RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING......................................................................................................... 641 ACTION CODE [TM-18] BACK LAMP RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING................................................................................................................... 642 ACTION CODE [TM-19] NEUTRAL OUTPUT SYSTEM HOT SHORT-CIRCUITING........................................................................................................................... 643 ACTION CODE [TM-20] FECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING........................................................................................................................... 644 ACTION CODE [TM-21] RECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING........................................................................................................................... 645 ACTION CODE [TM-22] 1ST ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING........................................................................................................................ 646 ACTION CODE [TM-23] 2ND ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING........................................................................................................................ 647 ACTION CODE [TM-24] 3RD ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING........................................................................................................................ 648 ACTION CODE [TM-25] 4TH ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING........................................................................................................................ 649 ACTION CODE [TM-26] LOCK-UP ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING.................................................................................................................... 650 ACTION CODE [TM-27] FAN PUMP EPC SOLENOID SYSTEM HOT SHORT-CIRCUITING.................................................................................................................... 651 ACTION CODE [TM-28] FAN REVERSE SOLENOID SYSTEM HOT SHORT-CIRCUITING..................................................................................................................... 652 ACTION CODE [TM-29] SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM FAILURE................................................................................................... 653 ACTION CODE [TM-30] TRAVEL DAMPER SOLENOID SYSTEM DISCONTINUITY OR GROUND FAULT.......................................................................................................... 654 TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WRK MODE).................................................................................................................................. 655 CONNECTOR TYPES AND MOUNTING LOCATIONS................................................................................................................................................... 657 CONNECTOR LAYOUT DRAWING................................................................................................................................................................. 665 WORK EQUIPMENT CONTROL SYSTEM DIAGRAM.................................................................................................................................................... 671 ERROR CODE [D193KA] (DEFECTIVE JOYSTICK STEERING CUT RELAY SYSTEM (MAIN SYSTEM DISCONNECTED)) IS DISPLAYED............................................................................... 674 ERROR CODE [D193KB] (THE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM IS GROUNDED PROPERLY) IS DISPLAYED.................................................................................... 675 ERROR CODE [DB90KK] (LOWERING WORK EQUIPMENT CONTROLLER POWER SUPPLY) IS DISPLAYED....................................................................................................... 676 ERROR CODE [DB92KK] (DEFECTIVE SOLENOID ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED....................................................................................................... 677 ERROR CODE [DB95KX] (DEFECTIVE 5V ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED............................................................................................................. 678 ERROR CODE [DD1ALD] (DEFECTIVE REMOTE POSITIONER UP SET SWITCH (GROUND FAULT)) IS DISPLAYED.............................................................................................. 680 ERROR CODE [DD1BLD] (DEFECTIVE REMOTE POSITIONER DOWN SET SWITCH (GROUND FAULT)) IS DISPLAYED............................................................................................ 681 ERROR CODE [DFAOKM] (DEFECTIVE NEUTRAL CAUTION FOR JOYSTICK WORK EQUIPMENT LEVER) IS DISPLAYED........................................................................................... 682 ERROR CODE [DK59KA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED........................................................ 683 ERROR CODE [DK59KY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORT CIRCUIT)) IS DISPLAYED................................................................................ 684 ERROR CODE [DK59L8] (DEFECTIVE LIFT ARM EPC POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED.................................................................... 685 ERROR CODE [DK5AKA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OF MAIN) (DISCONNECTION, GROUND OF SUB)) IS DISPLAYED.............................................. 686 ERROR CODE [DK5AKY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED................................................................................. 687 ERROR CODE [DK5BKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED.......................................................... 688 ERROR CODE [DK5BKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORTED)) IS DISPLAYED................................................................................ 689 ERROR CODE [DK5BL8] (DEFECTIVE INPUT SIGNAL FOR BUCKET EPC LEVER POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED............................................... 690 ERROR CODE [DK5CKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED........................................................... 691 ERROR CODE [DK5CKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED................................................................................... 692 ERROR CODE [DK5DKA] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED........................................................... 693 ERROR CODE [DK5DKY] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORT CIRCUIT)) IS DISPLAYED........................................................................... 694 ERROR CODE [DK5DL8] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED................................................ 695 ERROR CODE [DK5EKA] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED........................................................ 696 ERROR CODE [DK5EKY] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED................................................................................ 697 ERROR CODE [DK5FKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED............................................... 698 ERROR CODE [DK5FKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORTED)) IS DISPLAYED..................................................................... 699 ERROR CODE [DK5FKM] (JOYSTICK STEERING EPC LEVER NEUTRAL SYSTEM CAUTION) IS DISPLAYED.................................................................................................... 700 ERROR CODE [DK5FL8] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DEVIATION OF POSITIONAL SIGNALS OF MAIN AND SUB-CIRCUITS)) IS DISPLAYED.................... 701 ERROR CODE [DG5GKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUND FAULT OF SUB-CIRCUIT)) IS DISPLAYED............................................. 702 ERROR CODE [DK5GKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT SHORT CIRCUIT)) IS DISPLAYED................................................................ 703 ERROR CODE [DKA0KA] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (DISCONNECTION OR GROUND FAULT)) IS DISPLAYED................................................................................ 704 ERROR CODE [DKA0KY] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (SHORT CIRCUIT)) IS DISPLAYED................................................................................................ 705 ERROR CODE [DLE2LC] (DEFECTIVE ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED.................................................................................................................. 706 ERROR CODE [DLT3LC] (DEFECTIVE TRANSMISSION OUTPUT AXIS SPEED SENSOR SYSTEM (DISCONNECTED)) IS DISPLAYED................................................................................. 707 ERROR CODE [DUM1KB] (REMOTE POSITIONER RAISE LAMP SYSTEM GROUND FAULT) IS DISPLAYED...................................................................................................... 708 ERROR CODE [DUM2KB] (REMOTE POSITIONER LOWER LAMP SYSTEM GROUND FAULT) IS DISPLAYED...................................................................................................... 709 ERROR CODE [DW4PKA] (DISCONNECTED LIFT ARM RAISE EPC SOLENOID SYSTEM) IS DISPLAYED....................................................................................................... 710 ERROR CODE [DW4PKB] (LIFT ARM RAISE EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED....................................................................................................... 711 ERROR CODE [DW4QKA] (DISCONNECTED LIFT ARM LOWER EPC SOLENOID SYSTEM) IS DISPLAYED....................................................................................................... 712 ERROR CODE [DW4QKB] (LIFT ARM LOWER EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED....................................................................................................... 713 ERROR CODE [DW4RKA] (DISCONNECTED BUCKET TILT EPC SOLENOID SYSTEM) IS DISPLAYED.......................................................................................................... 714 ERROR CODE [DW4RKB] (BUCKET TILT EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED.......................................................................................................... 715 ERROR CODE [DW4SKA] (BUCKET DUMP EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED......................................................................................................... 716 ERROR CODE [DW4SKB] (BUCKET DUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED.......................................................................................................... 717 ERROR CODE [DWM1KA] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED............................................................................................. 718 ERROR CODE [DWM1KB] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED.............................................................................................. 719 ERROR CODE [DWN6KA] (LIFT ARM RAISE MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED..................................................................................................... 720 ERROR CODE [DWN6KB] (LIFT ARM RAISE MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED...................................................................................................... 721 ERROR CODE [DWN7KA] (LIFT ARM FLOATING MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED.................................................................................................. 722 ERROR CODE [DWN7KB] (LIFT ARM FLOATING MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED................................................................................................... 723 ERROR CODE [DWN8KA] (BUCKET TILT MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED........................................................................................................ 724 ERROR CODE [DWN8KB] (BUCKET TILT MAGNET DETENT SYSTEM FAILURE (POWER SUPPLY SYSTEM GROUND FAULT)) IS DISPLAYED........................................................................... 725 ERROR CODE [DXHJKA] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED................................................................................................. 726 ERROR CODE [DXHJKB] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED.................................................................................................. 727 ERROR CODE [DXHKKA] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED................................................................................................ 728 ERROR CODE [DXHKKB] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED................................................................................................. 729 ERROR CODE [DXHLKA] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED........................................................................................ 730 ERROR CODE [DXHLKB] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED......................................................................................... 731 ERROR CODE [DXHMKA] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED......................................................................................... 732 ERROR CODE [DXHMKB] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED.......................................................................................... 733 ACTION CODE [WRK-1] DEFECTIVE LIFT ARM LOCK SWITCH SYSTEM................................................................................................................................ 734 ACTION CODE [WRK-2] DEFECTIVE REMOTE POSITIONER RAISE SETTING SWITCH SYSTEM.............................................................................................................. 735 ACTION CODE [WRK-3] DEFECTIVE REMOTE POSITIONER LOWER SETTING SWITCH SYSTEM.............................................................................................................. 736 ACTION CODE [WRK-4] DEFECTIVE REMOTE POSITIONER RAISE SELECTION SWITCH SYSTEM............................................................................................................ 738 ACTION CODE [WRK-5] DEFECTIVE REMOTE POSITIONER LOWER ON/OFF SETTING SWITCH SYSTEM....................................................................................................... 740 ACTION CODE [WRK-6] DEFECTIVE BUCKET CYLINDER PROXIMITY SWITCH SYSTEM.................................................................................................................... 742 ACTION CODE [WRK-7] DEFECTIVE BUCKET CYLINDER FULL STROKE DETECTION SWITCH SYSTEM........................................................................................................ 744 ACTION CODE [WRK-8] DEFECTIVE SEMI-AUTOMATIC DIGGING HARD SELECTION SWITCH SYSTEM........................................................................................................ 745 ACTION CODE [WRK-9] DEFECTIVE SEMI-AUTOMATIC DIGGING SOFT SELECTION SWITCH SYSTEM........................................................................................................ 746 ACTION CODE [WRK-10] DEFECTIVE JOYSTICK ON/OFF SWITCH SYSTEM............................................................................................................................. 747 ACTION CODE [WRK-11] DEFECTIVE JOYSTICK STEERING SPEED HI/LO SWITCH SYSTEM............................................................................................................... 749 ACTION CODE [WRK-12] DEFECTIVE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM................................................................................................................. 750 ACTION CODE [WRK-13] HOT SHORT-CIRCUITED LIFT ARM RAISE MAGNET DETENT OUTPUT SYSTEM...................................................................................................... 751 ACTION CODE [WRK-14] HOT SHORT-CIRCUITED LIFT ARM FLOATING MAGNET DETENT OUTPUT SYSTEM................................................................................................... 752 ACTION CODE [WRK-15] HOT SHORT-CIRCUITED BUCKET TILT MAGNET DETENT OUTPUT SYSTEM......................................................................................................... 753 ACTION CODE [WRK-16] HOT SHORT-CIRCUITED WORK EQUIPMENT NEUTRAL LOCK SOLENOID OUTPUT SYSTEM.............................................................................................. 754 ACTION CODE [WRK-17] HOT SHORT-CIRCUITED LIFT ARM RAISE EPC SOLENOID SYSTEM.............................................................................................................. 755 ACTION CODE [WRK-18] HOT SHORT-CIRCUITED LIFT ARM LOWER EPC SOLENOID SYSTEM.............................................................................................................. 756 ACTION CODE [WRK-19] HOT SHORT-CIRCUITED BUCKET TILT EPC SOLENOID SYSTEM................................................................................................................. 757 ACTION CODE [WRK-20] HOT SHORT-CIRCUITED BUCKET DUMP EPC SOLENOID SYSTEM................................................................................................................. 758 ACTION CODE [WRK-21] HOT SHORT-CIRCUITED 3 VALVES EXTENSION EPC SOLENOID SYSTEM.......................................................................................................... 759 ACTION CODE [WRK-22] HOT SHORT-CIRCUITED 3 VALVES RETRACTION EPC SOLENOID SYSTEM......................................................................................................... 760 ACTION CODE [WRK-23] HOT SHORT-CIRCUITED JOYSTICK STEERING RIGHT EPC SOLENOID SYSTEM..................................................................................................... 761 ACTION CODE [WRK-24] HOT SHORT-CIRCUITED JOYSTICK STEERING LEFT EPC SOLENOID SYSTEM...................................................................................................... 762 ACTION CODE [WRK-25] DEFECTIVE BUCKET POSITIONER,LIFT ARM KICK-OUT AND FLOATING HOLDING FUNCTION......................................................................................... 763 ACTION CODE [WRK-26] DEFECTIVE LIFT ARM KICK-OUT FUNCTION AND CANCELLATION............................................................................................................... 765 ACTION CODE [WRK-27] DEFECTIVE BUCKET LEVELER FUNCTION AND CANCELLATION.................................................................................................................. 767 ACTION CODE [WRK-28] DEFECTIVE LIFT ARM FLOATING HOLDING AND CANCELLATION................................................................................................................ 769 TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE)................................................................................................................................................. 771 CONNECTOR TYPES AND MOUNTING LOCATIONS................................................................................................................................................... 773 CONNECTOR LAYOUT DRAWING................................................................................................................................................................. 781 MONITOR SYSTEM DIAGRAM................................................................................................................................................................... 787 ERROR CODE [2F00MA] DEFECTIVE PARKING BRAKE SYSTEM....................................................................................................................................... 791 ERROR CODE [2G42ZG] ACCUMULATOR OIL PRESSURE (FRONT CIRCUIT) LOW......................................................................................................................... 793 ERROR CODE [2G43ZG] ACCUMULATOR OIL PRESSURE (REAR BRAKE CIRCUIT) LOW.................................................................................................................... 794 ERROR CODE [AA1ANX] AIR CLEANER 1 CLOGGED................................................................................................................................................ 795 ERROR CODE [AB00L6] DEFECTIVE BATTERY CHARGING CIRCUIT (ALTERNATOR TERMINAL R SIGNAL DETECTED WHEN ENGINE STOPPED........................................................................ 797 ERROR CODE [AB00MA] DEFECTIVE BATTERY CHARGING CIRCUIT (NO ALTERNATOR TERMINAL R SIGNAL DETECTED,DETECTION FAILURE)...................................................................... 798 ERROR CODE [B@BAZG] ENGINE OIL PRESSURE LOW.............................................................................................................................................. 799 ERROR CODE [B@BAZK] ENGINE OIL LEVEL LOW................................................................................................................................................. 800 ERROR CODE [B@BCNS] ENGINE WATER TEMPERATURE OVERHEATING................................................................................................................................. 801 ERROR CODE [B@BCZK] ALARM INDICATING LOW COOLANT LEVEL................................................................................................................................... 802 ERROR CODE [B@HANS] HYDRAULIC OIL TEMPERATURE OVERHEATING................................................................................................................................ 803 ERROR CODE [B@CENS] TORQUE CONVERTER OIL TEMPERATURE OVERHEATING......................................................................................................................... 804 ERROR CODE [D182KZ] THE PREHEATER RELAY COIL IS DISCONNECTED OR SHIRT-CIRCUITED.......................................................................................................... 805 ERROR CODE [D5ZHL6] STARTING SWITCH C (IGN""C"") INPUT FAILURE........................................................................................................................... 807 ERROR CODE [DA80L4] AUTO GREASE INPUT FAILURE............................................................................................................................................ 808 ERROR CODE [DAF3KK] SW POWER SUPPLY (FOR OPERATION) = ON AND NSW POWER SUPPLY (FOR MEMORY) = OFF......................................................................................... 809 ERROR CODE [DAF5KP] 5-V POWER SUPPLY OUTPUT FAILURE...................................................................................................................................... 811 ERROR CODE [DAF6KP] 24-V POWER SUPPLY OUTPUT FAILURE..................................................................................................................................... 812 ERROR CODE [DAFBKM] WRONG INFORMATION ON MODEL SELECTION................................................................................................................................. 814 ERROR CODE [DAFSKQ] WRONG INFORMATION ON METER DISPLAY SELECTION......................................................................................................................... 815 ERROR CODE [DAQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND TRANSMISSION CONTROLLER) ..................................................................................... 816 ERROR CODE [DB2SKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND ENGINE CONTROLLER) ........................................................................................... 817 ERROR CODE [DBQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) ................................................................................... 818 ERROR CODE [DB9SKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) ................................................................................... 819 ERROR CODE [DD15LD] MONITOR PANEL MODE SELECTOR SWITCH 1 [■] (PANEL SW1) INPUT ERROR..................................................................................................... 820 ERROR CODE [DD16LD] MONITOR PANEL MODE SELECTOR SWITCH 1 [◇] (PANEL SW2) INPUT ERROR..................................................................................................... 821 ERROR CODE [DD17LD] THE MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SW3) INPUT CIRCUIT REMAINS CLOSED FOR MORE THAN ONE MINUTE....................................................... 822 ERROR CODE [DD18LD] MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SW4) INPUT ERROR..................................................................................................... 823 ERROR CODE [DD1CLD] SUB-TOTAL SWITCH FAILURE............................................................................................................................................. 824 ERROR CODE [DDS5L6] DECREASED STEERING OIL PRESSURE...................................................................................................................................... 825 ERROR CODE [DDY0LD] CANCEL SWITCH FAILURE................................................................................................................................................ 826 ERROR CODE [DGE2KX] ENGINE WATER TEMPERATURE SENSOR SYSTEM FAILURE....................................................................................................................... 827 ERROR CODE [DGE3L6] ABNORMAL CONNECTION OF ENGINE WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM...................................................................................... 828 ERROR CODE [DGH2KX] HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM FAILURE...................................................................................................................... 829 ERROR CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM FAILURE............................................................................................................... 830 ERROR CODE [DHE4L6] ENGINE OIL PRESSURE SENSOR SYSTEM FAILURE............................................................................................................................ 831 ERROR CODE [DHPCKX] BOTTOM PRESSURE SENSOR FAILURE....................................................................................................................................... 832 ERROR CODE [DHPDKX] HEAD PRESSURE SENSOR FAILURE......................................................................................................................................... 834 ERROR CODE [DKA0KX] LIFT ARM ANGLE SENSOR FAILURE........................................................................................................................................ 836 ERROR CODE [DV00KB] SHORT-CIRCUITED ALARM BUZZER OUTPUT SYSTEM........................................................................................................................... 837 ERROR CODE [DY30ME] THE EMERGENCY STEERING REMAINS ACTUATED FOR MORE THAN ONE MINUTE..................................................................................................... 838 ACTION CODE [MON-1] THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT UP WHEN THE PARKING BRAKE SWITCH IS TURNED ON (THE PARKING BRAKE INDICATOR SWITCH CIRCUIT SUFFERS A GROUND FAULT).... 840 ACTION CODE [MON-2] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (FRONT CIRCUIT)............................................................ 842 ACTION CODE [MON-3] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (REAR CIRCUIT)............................................................. 843 ACTION CODE [MON-4] THE AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT ON............................................................................................................ 844 ACTION CODE [MON-5] THE ENGINE HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON.................................................................................................................. 846 ACTION CODE [MON-6] THE ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT ON.................................................................................................................. 847 ACTION CODE [MON-7] THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON.......................................................................................................... 848 ACTION CODE [MON-8] THE RADIATOR WATER VOLUME CAUTION LAMP DOES NOT LIGHT ON............................................................................................................. 849 ACTION CODE [MON-9] THE HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON......................................................................................................... 850 ACTION CODE [MON-10] THE TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON................................................................................................. 851 ACTION CODE [MON-11] THE STEERING HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON............................................................................................................... 852 ACTION CODE [MON-12] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 [■] (PANEL SW1).......................................................................................................... 853 ACTION CODE [MON-13] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 [◇] (PANEL SW2).......................................................................................................... 854 ACTION CODE [MON-14] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 [<] (PANEL SW3).......................................................................................................... 855 ACTION CODE [MON-15] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 [>] (PANEL SW4).......................................................................................................... 856 ACTION CODE [MON-16] DEFECTIVE SUBTOTAL SWITCH........................................................................................................................................... 857 ACTION CODE [MON-17] DEFECTIVE CANCEL SWITCH............................................................................................................................................. 858 ACTION CODE [MON-18] DEFECTIVE BOTTOM PRESSURE SENSOR (HOT SHORT FAULT).................................................................................................................. 859 ACTION CODE [MON-19] DEFECTIVE HEAD SENSOR............................................................................................................................................... 860 ACTION CODE [MON-20] THE ALARM BUZZER DOES NOT SOUND OR STOP (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN BUZZER OUTPUT SYSTEM)................................................ 861 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)..................................................................................................................................... 862 H-1 THE MACHINE DOES NOT START........................................................................................................................................................... 863 H-2 THE LOCK-UP CLUTCH IS NOT RELEASED (THE ENGINE STOPS) (WHEN THE LOCK-UP CLUTCH IS PROVIDED).......................................................................................... 865 H-3a THE TRAVEL SPEED IS SLOW, THE THRUSTING FORCE IS WEAK,THE UPHILL TRAVELING POWER IS WEAK, AND THE GEAR IS NOT SHIFTED............................................................... 866 H-3b THE TORQUE CONVERTER LOCK-UP CLUTCH IS NOT LET IN (IF THE LOCK-UP CLUTCH IS EQUIPPED)............................................................................................... 868 H-4 SHOCKS ARE LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR.......................................................................................................................... 869 H-5 TIME LAG IS LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR......................................................................................................................... 871 H-6 THE TORQUE CONVERTER OIL TEMPERATURE IS HIGH......................................................................................................................................... 873 H-7 THE STEERING WHEEL DOES NOT TURN..................................................................................................................................................... 874 H-8 THE STEERING WHEEL IS HEAVY.......................................................................................................................................................... 875 H-9 THE STEERING WHEEL FLUCTUATES OR IS STRONGLY SHOCKED................................................................................................................................. 876 H-10 THE MACHINE STEERS TO ONE SIDE WHEN TRAVELING....................................................................................................................................... 876 H-11 THE RIGHT AND LEFT SWING RADII ARE DIFFERENT........................................................................................................................................ 876 H-12 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL....................................................................................................................................... 877 H-13 THE BRAKE IS NOT RELEASED OR IS DRAGGED............................................................................................................................................. 878 H-14 THE PARKING BRAKE IS NOT RELEASED OR IS DRAGGED..................................................................................................................................... 879 H-15 THE LIFT ARM DOES NOT RISE.......................................................................................................................................................... 880 H-16 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT.............................................................................................................. 881 H-17 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT.................................................................................................................... 882 H-18 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR)..................................................................................................... 882 H-19 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN........................................................................................................................................ 882 H-20 THE LIFT ARM WOBBLES DURING OPERATION............................................................................................................................................... 882 H-21 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "RAISE",THE LIFT ARM FALLS TEMPORARILY............................................................................................ 883 H-22 THE BUCKET DOES NOT TILT BACK....................................................................................................................................................... 884 H-23 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT................................................................................................................... 885 H-24 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILTING-BACK...................................................................................................................... 886 H-25 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET..................................................................................................................................... 886 H-26 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN.......................................................................................................................................... 886 H-27 THE BUCKET WOBBLES DURING TRAVEL WITH LOAD (THE WORK EQUIPMENT VALVE IS SET TO "HOLD").............................................................................................. 887 H-28 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "TILT",THE BUCKET FALLS TEMPORARILY............................................................................................... 887 H-29 THE CONTROL LEVERS OF LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY............................................................................................................ 888 H-30 ECSS (TRAVEL DAMPER) DOES NOT WORK, AND THERE IS PITCING AND BOUNCING............................................................................................................... 889 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)................................................................................................................................................ 890 CONNECTOR TYPES AND MOUNTING LOCATIONS................................................................................................................................................... 891 CONNECTOR LAYOUT DRAWING................................................................................................................................................................. 899 ELECTRICAL SYSTEM DIAGRAM................................................................................................................................................................ 905 ACTION CODE [E-1-a] (THE ENGINE DOES NOT START. (STARTING SYSTEM))....................................................................................................................... 906 ACTION CODE [E-1-b] (THE ENGINE DOES NOT START.(ENGINE STOP SOLENOID SYSTEM))............................................................................................................ 910 ACTION CODE [E-2] (THE ENGINE DOES NOT STOP)............................................................................................................................................. 912 ACTION CODE [E-3] (PREHEATING IS IMPOSSIBLE OR STAYS OPERATED)........................................................................................................................... 914 ACTION CODE [E-4] (THE ENGINE POWER MODES CANNOT BE SELECTED)............................................................................................................................ 916 ACTION CODE [E-5] (ALL OF THE BUCKET POSITIONER, LIFT ARM KICK-OUT, AND FLOATING HOLDER DO NOT FUNCTION)................................................................................. 918 ACTION CODE [E-6] (THE LIFT ARM KICK-OUT DOES NOT FUNCTION OR CANNOT BE RELEASED)........................................................................................................ 920 ACTION CODE [E-7] (THE BUCKET POSITIONER DOES NOT FUNCTION OR CANNOT BE RELEASED)........................................................................................................ 922 ACTION CODE [E-8] (THE LIFT ARM FLOATING HOLDER DOES NOT FUNCTION OR CANNOT BE RELEASED)................................................................................................. 924 ACTION CODE [E-9] (THE FRONT WIPER DOES NOT FUNCTION).................................................................................................................................... 925 ACTION CODE [E-10] (THE REAR WIPER DOES NOT FUNCTION).................................................................................................................................... 928 ACTION CODE [E-11] (THE SIDE WIPER DOES NOT FUNCTION (OPT)).............................................................................................................................. 929 ACTION CODE [E-12] (THE WIND WASHER DOES NOT FUNCTION)................................................................................................................................... 930 ACTION CODE [E-13] (THE HEADLAMP (LO BEAM) DOES NOT LIGHT ON)............................................................................................................................ 933 ACTION CODE [E-14] (THE HEADLAMP (HI BEAM) DOES NOT LIGHT ON)............................................................................................................................ 936 ACTION CODE [E-15] (THE CLEARANCE LAMP DOES NOT LIGHT ON (SMALL LAMP))................................................................................................................... 938 ACTION CODE [E-16] (THE TURN SIGNAL DOES NOT BLINK)...................................................................................................................................... 939 ACTION CODE [E-17] (THE HORN DOES NOT SOUND)............................................................................................................................................. 941 ACTION CODE [E-18] (THE AIR CONDITIONER DOES NOT WORK OR DOES NOT STOP).................................................................................................................. 943 TROUBLESHOOTING OF ENGINE (S MODE)........................................................................................................................................................... 946 METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................................................................... 947 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)............................................................................................................................ 951 S-2 ENGINE DOES NOT START................................................................................................................................................................ 952 (1) ENGINE DOES NOT TURN............................................................................................................................................................. 952 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)......................................................................................................... 953 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)....................................................................................................... 954 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)................................................................................................................................. 955 S-4 ENGINE STOPS DURING OPERATIONS....................................................................................................................................................... 956 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)............................................................................................................................................ 957 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)................................................................................................................................................. 958 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)....................................................................................................................................... 959 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).............................................................................................................................. 960 S-9 OIL BECOMES CONTAMINATED QUICKLY..................................................................................................................................................... 961 S-10 FUEL CONSUMPTION IS EXCESSIVE....................................................................................................................................................... 962 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN............................................................................................................. 963 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).......................................................................................................................... 964 S-13 OIL LEVEL RISES (COOLANT, FUEL IN OIL).............................................................................................................................................. 965 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).................................................................................................................................... 966 S-15 ABNORMAL NOISE IS MADE.............................................................................................................................................................. 967 S-16 VIBRATION IS EXCESSIVE.............................................................................................................................................................. 968 30 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................................... 969 METHOD OF USING MANUAL........................................................................................................................................................................... 970 PRECAUTIONS WHEN CARRYING OUT OPERATION.......................................................................................................................................................... 971 SPECIAL TOOL LIST................................................................................................................................................................................ 974 REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY...................................................................................................................................................... 990 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY............................................................................................................................................... 994 REMOVAL AND INSTALLATION OF RADIATOR AND FAN MOTOR ASSEMBLY...................................................................................................................................... 999 REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY.................................................................................................................................................1001 REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP..................................................................................................................................................1001 REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY...............................................................................................................................................1004 REMOVAL AND INSTALLATION OF FAN AND FAN MOTOR ASSEMBLY...........................................................................................................................................1006 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY...................................................................................................................................................1007 REMOVAL AND INSTALLATION OF PARKING BRAKE DISC PLATE.............................................................................................................................................1009 REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...........................................................................................................................1012 DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY................................................................................................................................................1016 DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH PACK ASSEMBLY....................................................................................................................................1028 DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY...............................................................................................................................................1043 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (STANDARD SPECIFICATION)...................................................................................................................1051 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (LOCK-UP SPECIFICATION)....................................................................................................................1055 REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY...................................................................................................................................................1061 REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY..................................................................................................................................................1064 DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY................................................................................................................................................1065 DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY................................................................................................................................................1075 REMOVAL AND INSTALLATION OF CENTER HINGE PIN.....................................................................................................................................................1095 REMOVAL AND INSTALLATION OF CAB ASSEMBLY.........................................................................................................................................................1102 REMOVAL AND INSTALLATION OF CAB AND FLOOR FRAME ASSEMBLY.........................................................................................................................................1103 REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)...................................................................................................................................1106 REMOVAL AND INSTALLATION OF TRANSMISSION, WORK EQUIPMENT, AND PPC PUMP ASSEMBLY..................................................................................................................1114 REMOVAL AND INSTALLATION OF STEERING, SWITCHING, AND FAN PUMP ASSEMBLY...........................................................................................................................1115 REMOVAL AND INSTALLATION OF STEERING DEMAND VALVE ASSEMBLY.......................................................................................................................................1116 REMOVAL AND INSTALLATION OF TRAVEL DUMPER VALVE ASSEMBLY.........................................................................................................................................1117 REMOVAL AND INSTALLATION OF WORK EQUIPMENT VALVE ASSEMBLY........................................................................................................................................1118 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY (STEERING, LIFT, AND BUCKET CYLINDER ASSEMBLY)...........................................................................................1120 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY..............................................................................................................................................1128 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY..............................................................................................................................................1130 REMOVAL AND INSTALLATION OF COUNTER WEIGHT.......................................................................................................................................................1134 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT.................................................................................................................................................1135 REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY..................................................................................................................................1138 DISASSEMBLY, ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY................................................................................................................................................1139 90 OTHERS............................................................................................................................................................................................1149 POWER TRAIN OIL CIRCUIT DIAGRAM (WITHOUT TORQUE CONVERTER LOCKUP CLUTCH).........................................................................................................................1150 POWER TRAIN OIL CIRCUIT DIAGRAM (WITH TORQUE CONVERTER LOCKUP CLUTCH)............................................................................................................................1151 BRAKE OIL CIRCUIT DIAGRAM........................................................................................................................................................................1152 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.........................................................................................................................................................1153 ELECTRICAL CIRCUIT DIAGRAM.......................................................................................................................................................................1154 1/8 (1/4)....................................................................................................................................................................................1154 1/8 (2/4)....................................................................................................................................................................................1155 1/8 (3/4)....................................................................................................................................................................................1156 1/8 (4/4)....................................................................................................................................................................................1157 2/8 (1/4)....................................................................................................................................................................................1158 2/8 (2/4)....................................................................................................................................................................................1159 3/8 (3/4)....................................................................................................................................................................................1160 4/8 (4/4)....................................................................................................................................................................................1161 3/8..........................................................................................................................................................................................1162 4/8..........................................................................................................................................................................................1163 5/8..........................................................................................................................................................................................1164 6/8..........................................................................................................................................................................................1165 7/8..........................................................................................................................................................................................1166 8/8..........................................................................................................................................................................................1167
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PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]