Komatsu WA380-5 Wheel Loader Shop Manual SEBM024713 – PDF DOWNLOAD

Komatsu WA380-5 Wheel Loader Shop Manual SEBM024713 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA380-5 Wheel Loader Shop Manual SEBM024713 – PDF DOWNLOAD

Language : English
Pages : 1240
Downloadable : Yes
File Type : PDF
Size: 80 MB

DESCRIPTION:

Komatsu WA380-5 Wheel Loader Shop Manual SEBM024713 – PDF DOWNLOAD

Machine model  Serial number
WA380-5             60001 and up

GENERAL PRECAUTIONS:

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.• Always wear safety glasses when hitting parts with a hammer.• Always wear safety glasses when grinding parts with a grinder, etc.3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work.4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.5. Keep all tools in good condition and learn the correct way to use them.6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

PREPARATIONS FOR WORK:

• 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
• 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
• 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
• 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

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 WA380-5 Wheel Loader Shop Manual SEBM024713 – PDF DOWNLOAD

COVER 1
CONTENTS 2
LIST OF REVISED PAGES 3
SAFETY 9
SAFETY NOTICE 9
FOREWORD 11
GENERAL 11
HOW TO READ THE SHOP MANUAL 12
HOISTING INSTRUCTIONS 13
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 14
COATING MATERIALS 16
STANDARD TIGHTENING TORQUE 18
ELECTRIC WIRE CODE 21
CONVERSION TABLE 22
UNITS 28
01 GENERAL 29
GENERAL ASSEMBLY DRAWING 30
SPECIFICATIONS 31
WEIGHT TABLE 35
LIST OF LUBRICANT AND COOLANT 37
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD 39
COOLING SYSTEM 40
ENGINE MOUNT, TRANSMISSION MOUNT 41
POWER TRAIN 42
POWER TRAIN SYSTEM DIAGRAM 43
DRIVE SHAFT (PROPELLER SHAFT) 46
TORQUE CONVERTER, TRANSMISSION PIPING 47
TORQUE CONVERTER 48
TRANSMISSION 56
TRANSMISSION CONTROL VALVE 72
AXLE 90
DIFFERENTIAL 92
FINAL DRIVE 101
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 (IF EQUIPPED) 132
EMERGENCY STEERING MOTOR (IF EQUIPPED) 133
STEERING CYLINDER 134
JOYSTICK STEERING LEVER (IF EQUIPPED) 136
STEERING LEVER (IF EQUIPPED) 137
STEERING SWITCH VALVE (IF EQUIPPED) 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
HYDRAULI PIPING 166
WORK EQUIPMENT CONTROL LEVER 169
HYDRAULIC TANK 171
TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PILOT CONTROL PUMPS 173
PPC RELIEF VALVE 175
E C S S VALVE (IF EQUIPPED) 177
WORK EQUIPMENT CONTROL VALVE 179
WORK EQUIPMENT PPC VALVE 196
PPC VALVE (FOR MULTI FUNCTION MONO LEVER) 202
EPC SOLENOID VALVE (IF EQUIPPED) 208
SHUT OFF VALVE (IF EQUIPPED) 211
ATTACHMENT PPC VALVE (IF EQUIPPED) 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 (IF EQUIPPED) 240
MACHINE MONITORING SYSTEM 241
MACHINE MONITOR 248
TRANSMISSION CONTROL SYSTEM 318
TRANSMISSION CONTROLLER 346
WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED) 348
WORK EQUIPMENT CONTROLLER (IF EQUIPPED) 364
ELECTRIC TRANSMISSION CONTROL 366
KICK DOWN, HOLD SWITCH 370
ENGINE STARTING CIRCUIT 371
ENGINE STOP CIRCUIT 373
PREHEATING CIRCUIT 374
ENGINE POWER MODE SELECTOR CIRCUIT 375
PARKING BRAKE CIRCUIT 376
SENSORS 380
20 TESTING AND ADJUSTING 391
STANDARD VALUE TABLE FOR ENGINE 392
STANDARD VALUE TABLE FOR CHASSIS 393
TESTING AND ADJUSTING 401
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 403
MEASURING ENGINE SPEED 404
MEASURING EXHAUST COLOR 406
MEASURING EXHAUST TEMPERATURE 407
ADJUSTING VALVE CLEARANCE 408
MEASURING COMPRESSION PRESSURE 410
MEASURING BLOW-BY PRESSURE 411
MEASURING ENGINE OIL PRESSURE 412
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) 413
TESTING AND ADJUSTING FUEL INJECTION TIMING 414
ADJUSTING ENGINE SPEED SENSOR 415
BLEEDING AIR FROM FUEL CIRCUIT 416
ADJUSTING ENGINE STOP SOLENOID 417
ADJUSTING ACCELERATOR PEDAL 419
ADJUSTING TRANSMISSION SPEED SENSOR 421
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE 422
DRAWING OF SPECIAL TOOL 426
PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT 427
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS 428
TESTING AND ADJUSTING STEERING CONTROL 430
TESTING AND ADJUSTING STEERING OIL PRESSURE 431
TESTING HYDRAULIC FAN 433
MEASURING BRAKE OIL PRESSURE 434
TESTING WEAR OF WHEEL BRAKE DISC 436
BLEEDING AIR FROM BRAKE CIRCUIT 437
TESTING WEAR OF PARKING BRAKE DISC 438
MANUAL RELEASE METHOD FOR PARKING BRAKE 439
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE 440
TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE 442
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE 444
TESTING AND ADJUSTING BUCKET POSITIONER 446
TESTING AND ADJUSTING LIFT ARM KICK-OUT 447
CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP 448
ADJUSTING MACHINE MONITOR 449
TESTING AND ADJUSTING LOAD METER 452
BLEEDING AIR 456
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 457
RELEASING REMAINING PRESSURE IN E C S S CIRCUIT 457
PM CLINIC INSPECTION TABLE 458
TROUBLESHOOTING 461
POINTS TO REMEMBER WHEN TROUBLESHOOTING 462
SEQUENCE OF EVENTS IN TROUBLESHOOTING 463
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 464
CHECKS BEFORE TROUBLESHOOTING 472
SPECIAL FUNCTIONS OF MACHINE MONITOR 474
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS 509
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 518
T-ADAPTER TABLE 541
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (TM MODE) 545
CONNECTOR TYPES AND MOUNTING LOCATIONS 549
CONNECTOR LAYOUT DRAWING 558
TRANSMISSION CONTROL SYSTEM DIAGRAM 564
ERROR CODE [1500L1] (DOUBLE ENGAGEMENT DETECTED) IS DISPLAYED 567
ERROR CODE [15SAL1] (F_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 568
ERROR CODE [15SALH] (F_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 569
ERROR CODE [15SBL1] (R_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 570
ERROR CODE [15SBLH] (R_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 571
ERROR CODE [15SEL1] (1ST_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 572
ERROR CODE [15SELH] (1ST_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 573
ERROR CODE [15SFL1] (2ND_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 574
ERROR CODE [15SFLH] (2ND_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 575
ERROR CODE [15SGL1] (3RD_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 576
ERROR CODE [15SGLH] (3RD_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 577
ERROR CODE [15SHL1] (4TH_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 578
ERROR CODE [15SHLH] (4TH_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 579
ERROR CODE [15SJL1] (LOCKUP_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 580
ERROR CODE [15SJLH] (LOCKUP_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 581
ERROR CODE [989F00] (TRANSMISSION PROTECTION CAUTION) IS DISPLAYED 582
ERROR CODE [B@C7NS] (REAR BRAKE COOLING OIL OVERHEAT) IS DISPLAYED 584
ERROR CODE [D150KA] (EMERGENCY STEERING RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 585
ERROR CODE [D150KB] (EMERGENCY STEERING RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 586
ERROR CODE [D160KA] (BACKUP LAMP RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 587
ERROR CODE [D160KB] (BACKUP LAMP RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 588
ERROR CODE [D191KA] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 590
ERROR CODE [D191KB] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 592
ERROR CODE [D192KA] (E C S S R RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 594
ERROR CODE [D192KB] (E C S S RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 595
ERROR CODE [D198KB] (GROUND FAULT IN THE LOW TEMPERATURE BYPASS RELAY SYSTEM) IS DISPLAYED 596
ERROR CODE [D198KY] (HOT-SHORT IN THE LOW-TEMPERATURE BYPASS RELAY SYSTEM) IS DISPLAYED 597
ERROR CODE [DAQ0KK] (CONTROLLER POWER SUPPLY VOLTAGE LOWERED) IS DISPLAYED 598
ERROR CODE [DAQ2KK] (DEFECTIVE SOLENOID POWER SUPPLY SYSTEM) IS DISPLAYED 599
ERROR CODE [DAQ9KQ] (MODEL SELECTION SIGNAL MISMATCH) IS DISPLAYED 600
ERROR CODE [DDK3KA] (RIGHT FNR SWITCH SIGNAL NOT INPUT) IS DISPLAYED 602
ERROR CODE [DDK3KB] (MULTIPLE RIGHT FNR SWITCH SIGNAL INPUT) IS DISPLAYED 604
ERROR CODE [DDK4KA] (JOYSTICK FORWARD/REVERSE SWITCH SIGNAL IS NOT INPUT) IS DISPLAYED 607
ERROR CODE [DDK4KB] (MULTIPLE JOYSTICK FORWARD/REVERSE SWITCH SIGNALS ARE INPUT) IS DISPLAYED 609
ERROR CODE [DDK5LD] (SHORT CIRCUIT WITH POWER SOURCE IN JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH) IS DISPLAYED 611
ERROR CODE [DDK6KA] (FORWARD-REVERSE LEVER SIGNAL NOT INPUT) IS DISPLAYED 612
ERROR CODE [DDK6KB] (MULTIPLE FORWARD-REVERSE LEVER SIGNAL INPUT) IS DISPLAYED 614
ERROR CODE [DDS5KA] (STEERING PRESSURE SWITCH DISCONNECTED) IS DISPLAYED 616
ERROR CODE [DDS5KB] (STEERING PRESSURE SWITCH GROUNDED) IS DISPLAYED 617
ERROR CODE [DDT0L4] (MANUAL/AUTO-SHIFT SELECTOR SWITCH SELECTION FAILURE) IS DISPLAYED 618
ERROR CODE [DDT4LD] (GROUND FAULT OF TRANSMISSION CUT-OFF SETTING SWITCH) IS DISPLAYED 620
ERROR CODE [DDW9LD] (GROUND FAULT OF KICKDOWN SWITCH SYSTEM) IS DISPLAYED 621
ERROR CODE [DDWLLD] (GROUND FAULT OF HOLD SWITCH SYSTEM) IS DISPLAYED 624
ERROR CODE [DF10KA] (NO INPUT OF GEAR SHIFT LEVER SIGNAL) IS DISPLAYED 626
ERROR CODE [DF10KB] (INPUT OF MULTIPLE GEAR SHIFT LEVER SIGNALS) IS DISPLAYED 628
ERROR CODE [DGF1KX] (TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM FAILURE) IS DISPLAYED 630
ERROR CODE [DGR2KA] (REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM DISCONNECTION) IS DISPLAYED 631
ERROR CODE [DGR2KB] (GROUND FAULT OF REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED 632
ERROR CODE [DHT1KX] (TRANSMISSION CUT-OFF (LEFT BRAKE PRESSURE SENSOR) SIGNAL DISCONTINUITY) IS DISPLAYED 633
ERROR CODE [DLE2KA] (ENGINE REVOLUTION SENSOR SYSTEM DISCONTINUITY) IS DISPLAYED 634
ERROR CODE [DLE2LC] (ENGINE REVOLUTION SENSOR FAILURE) IS DISPLAYED 635
ERROR CODE [DLT3KA] (SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM DISCONTINUITY) IS DISPLAYED 636
ERROR CODE [DT20KB] (GROUND FAULT OF BUILT-IN INDICATOR LAMP SYSTEM OF TRANSMISSION CUT-OFF SWITCH) IS DISPLAYED 637
ERROR CODE [DW7BKA] (FAN PUMP REVERSE SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 638
ERROR CODE [DW7BKB] (FAN PUMP REVERSE SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 639
ERROR CODE [DW7CKA] (SWITCH PUMP CUT-OFF RELAY DISCONTINUITY) IS DISPLAYED 640
ERROR CODE [DW7CKB] (SWITCH PUMP CUT-OFF RELAY GROUND FAULT) IS DISPLAYED 641
ERROR CODE [DX16KA] (FAN PUMP EPC SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 642
ERROR CODE [DX16KB] (FAN PUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 643
ERROR CODE [DXH1KA] (LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 644
ERROR CODE [DXH1KB] (LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 645
ERROR CODE [DXH4KA] (1ST_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 646
ERROR CODE [DXH4KB] (1ST_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 647
ERROR CODE [DXH5KA] (2ND_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 648
ERROR CODE [DXH5KB] (2ND_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 649
ERROR CODE [DXH6KA] (3RD_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 650
ERROR CODE [DXH6KB] (3RD_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 651
ERROR CODE [DXH7KA] (R_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 652
ERROR CODE [DXH7KB] (R_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 653
ERROR CODE [DXH8KA] (F_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 654
ERROR CODE [DXH8KB] (F_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 655
ERROR CODE [DXHHKA] (4TH_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 656
ERROR CODE [DXHHKB] (4TH_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 657
ERROR CODE [DY30MA] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE)) 658
ERROR CODE [DY30MC] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE)) 660
TROUBLESHOOTING CODE [TM-1] DISCONTINUITY OR HOT SHORT-CIRCUITING OF KICKDOWN SWITCH SYSTEM 662
TROUBLESHOOTING CODE [TM-2] HOLD SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING 664
TROUBLESHOOTING CODE [TM-3] TORQUE CONVERTER LOCK-UP SWITCH SYSTEM FAILURE 666
TROUBLESHOOTING CODE [TM-4] NEUTRALIZER SIGNAL (PARKING BRAKE SWITCH SIGNAL) SYSTEM FAILURE 668
TROUBLESHOOTING CODE [TM-5] EMERGENCY STEERING SWITCH (MOTOR-DRIVEN EMERGENCY STEERING OPERATION SWITCH) SIGNAL SYSTEM FAILURE 670
TROUBLESHOOTING CODE [TM-6] TRANSMISSION CUT-OFF SWITCH SYSTEM DISCONTINUITY OR GROUND FAULT 672
TROUBLESHOOTING CODE [TM-7] TRANSMISSION CUT-OFF SETTING SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING 673
TROUBLESHOOTING CODE [TM-8] TRANSMISSION CUT-OFF (LEFT BRAKE SENSOR) SIGNAL SHORT-CIRCUITING 674
TROUBLESHOOTING CODE [TM-9a] JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH SYSTEM FAILURE (DISCONTINUITY OR GROUND FAULT) 675
TROUBLESHOOTING CODE [TM-9b] JOYSTICK ON/OFF CHANGE OVER SWITCH SYSTEM FAILURE 676
TROUBLESHOOTING CODE [TM-10] FNR SWITCH MODE CHANGE OVER SWITCH SYSTEM FAILURE 678
TROUBLESHOOTING CODE [TM-11] STARTING SWITCH “C” (IGN_C) SIGNAL SYSTEM FAILURE 680
TROUBLESHOOTING CODE [TM-12] ENGINE POWER MODE SWITCH DISCONTINUITY OR GROUND FAULT 682
TROUBLESHOOTING CODE [TM-13] TRAVEL DAMPER ON/OFF SWITCH DISCONTINUITY OR GROUND FAULT 683
TROUBLESHOOTING CODE [TM-14] HYDRAULIC FAN REVERSE SWITCH SIGNAL SYSTEM HOT SHORT-CIRCUITING OR DISCONTINUITY 684
TROUBLESHOOTING CODE [TM-15] MOTOR-DRIVEN EMERGENCY STEERING RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING 685
TROUBLESHOOTING CODE [TM-16] TRAVEL DAMPER RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING 686
TROUBLESHOOTING CODE [TM-17] SWITCH PUMP CUT-OFF RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING 687
TROUBLESHOOTING CODE [TM-18] BACK LAMP RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING 688
TROUBLESHOOTING CODE [TM-19] NEUTRAL OUTPUT SYSTEM HOT SHORT-CIRCUITING 689
TROUBLESHOOTING CODE [TM-20] FECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING 690
TROUBLESHOOTING CODE [TM-21] RECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING 691
TROUBLESHOOTING CODE [TM-22] 1ST ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING 692
TROUBLESHOOTING CODE [TM-23] 2ND ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING 693
TROUBLESHOOTING CODE [TM-24] 3RD ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING 694
TROUBLESHOOTING CODE [TM-25] 4TH ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING 695
TROUBLESHOOTING CODE [TM-26] LOCK-UP ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING 696
TROUBLESHOOTING CODE [TM-27] FAN PUMP EPC SOLENOID SYSTEM HOT SHORT-CIRCUITING 697
TROUBLESHOOTING CODE [TM-28] FAN REVERSE SOLENOID SYSTEM HOT SHORT-CIRCUITING 698
TROUBLESHOOTING CODE [TM-29] SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM FAILURE 699
TROUBLESHOOTING CODE [TM-30] E C S S SOLENOID SYSTEM DISCONTINUITY OR GROUND FAULT 700
TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WRK MODE) 701
CONNECTOR TYPES AND MOUNTING LOCATIONS 705
CONNECTOR LAYOUT DRAWING 714
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 722
FAILURE CODE [D193KA] (DEFECTIVE JOYSTICK STEERING CUT RELAY SYSTEM (MAIN SYSTEM DISCONNECTED)) IS DISPLAYED 725
FAILURE CODE [D193KB] (THE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM IS GROUNDED PROPERLY) IS DISPLAYED 726
FAILURE CODE [DB90KK] (LOWERING WORK EQUIPMENT CONTROLLER POWER SUPPLY) IS DISPLAYED 727
FAILURE CODE [DB92KK] (DEFECTIVE SOLENOID ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED 728
FAILURE CODE [DB95KX] (DEFECTIVE 5 V ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED 730
FAILURE CODE [DD1ALD] (DEFECTIVE REMOTE POSITIONER UP SET SWITCH (GROUND FAULT)) IS DISPLAYED 732
FAILURE CODE [DD1BLD] (DEFECTIVE REMOTE POSITIONER DOWN SET SWITCH (GROUND FAULT)) IS DISPLAYED 733
FAILURE CODE [DFA0KM] (DEFECTIVE NEUTRAL CAUTION FOR JOYSTICK WORK EQUIPMENT LEVER) IS DISPLAYED 734
FAILURE CODE [DK59KA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 735
FAILURE CODE [DK59KY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORT CIRCUIT)) IS DISPLAYED 736
FAILURE CODE [DK59L8] (DEFECTIVE LIFT ARM EPC POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED 737
FAILURE CODE [DK5AKA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OF MAIN) (DISCONNECTION,GROUND OF SUB)) IS DISPLAYED 738
FAILURE CODE [DK5AKY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED 739
FAILURE CODE [DK5BKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 740
FAILURE CODE [DK5BKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORTED)) IS DISPLAYED 741
FAILURE CODE [DK5BL8] (DEFECTIVE INPUT SIGNAL FOR BUCKET EPC LEVER POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED 742
FAILURE CODE [DK5CKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 743
FAILURE CODE [DK5CKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED 744
FAILURE CODE [DK5DKA] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 745
FAILURE CODE [DK5DKY] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORT CIRCUIT)) IS DISPLAYED 746
FAILURE CODE [DK5DL8] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED 747
FAILURE CODE [DK5EKA] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 748
FAILURE CODE [DK5EKY] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED 749
FAILURE CODE [DK5FKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 750
FAILURE CODE [DK5FKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORTED)) IS DISPLAYED 751
FAILURE CODE [DK5FKM] (JOYSTICK STEERING EPC LEVER NEUTRAL SYSTEM CAUTION) IS DISPLAYED 752
FAILURE CODE [DK5FL8] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DEVIATION OF POSITIONAL SIGNALS OF MAIN AND SUB-CIRCUITS)) IS DISPLAYED 753
FAILURE CODE [DG5GKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUND FAULT OF SUB-CIRCUIT)) IS DISPLAYED 754
FAILURE CODE [DK5GKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT SHORT CIRCUIT)) IS DISPLAYED 755
FAILURE CODE [DKA0KA] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (DISCONNECTION OR GROUND FAULT)) IS DISPLAYED 756
FAILURE CODE [DKA0KY] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (SHORT CIRCUIT)) IS DISPLAYED 757
FAILURE CODE [DLE2LC] (DEFECTIVE ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 758
FAILURE CODE [DLT3LC] (DEFECTIVE TRANSMISSION OUTPUT AXIS SPEED SENSOR SYSTEM (DISCONNECTED)) IS DISPLAYED 759
FAILURE CODE [DUM1KB] (REMOTE POSITIONER RAISE LAMP SYSTEM GROUND FAULT) IS DISPLAYED 760
FAILURE CODE [DUM2KB] (REMOTE POSITIONER LOWER LAMP SYSTEM GROUND FAULT) IS DISPLAYED 761
FAILURE CODE [DW4PKA] (DISCONNECTED LIFT ARM RAISE EPC SOLENOID SYSTEM) IS DISPLAYED 762
FAILURE CODE [DW4PKB] (LIFT ARM RAISE EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 763
FAILURE CODE [DW4QKA] (DISCONNECTED LIFT ARM LOWER EPC SOLENOID SYSTEM) IS DISPLAYED 764
FAILURE CODE [DW4QKB] (LIFT ARM LOWER EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 765
FAILURE CODE [DW4RKA] (DISCONNECTED BUCKET TILT EPC SOLENOID SYSTEM) IS DISPLAYED 766
FAILURE CODE [DW4RKB] (BUCKET TILT EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 767
FAILURE CODE [DW4SKA] (BUCKET DUMP EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 768
FAILURE CODE [DW4SKB] (BUCKET DUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 769
FAILURE CODE [DWM1KA] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 770
FAILURE CODE [DWM1KB] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 771
FAILURE CODE [DWN6KA] (LIFT ARM RAISE MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED 772
FAILURE CODE [DWN6KB] (LIFT ARM RAISE MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED 773
FAILURE CODE [DWN7KA] (LIFT ARM FLOATING MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED 774
FAILURE CODE [DWN7KB] (LIFT ARM FLOATING MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED 775
FAILURE CODE [DWN8KA] (BUCKET TILT MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED 776
FAILURE CODE [DWN8KB] (BUCKET TILT MAGNET DETENT SYSTEM FAILURE (POWER SUPPLY SYSTEM GROUND FAULT)) IS DISPLAYED 777
FAILURE CODE [DXHJKA] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 778
FAILURE CODE [DXHJKB] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 779
FAILURE CODE [DXHKKA] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 780
FAILURE CODE [DXHKKB] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 781
FAILURE CODE [DXHLKA] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 782
FAILURE CODE [DXHLKB] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 783
FAILURE CODE [DXHMKA] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 784
FAILURE CODE [DXHMKB] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 785
TROUBLESHOOTING CODE [WRK-1] DEFECTIVE LIFT ARM LOCK SWITCH SYSTEM 786
TROUBLESHOOTING CODE [WRK-2] DEFECTIVE REMOTE POSITIONER RAISE SETTING SWITCH SYSTEM 787
TROUBLESHOOTING CODE [WRK-3] DEFECTIVE REMOTE POSITIONER LOWER SETTING SWITCH SYSTEM 788
TROUBLESHOOTING CODE [WRK-4] DEFECTIVE REMOTE POSITIONER RAISE SELECTION SWITCH SYSTEM 790
TROUBLESHOOTING CODE [WRK-5] DEFECTIVE REMOTE POSITIONER LOWER ON/OFF SWITCH SYSTEM 792
TROUBLESHOOTING CODE [WRK-6] DEFECTIVE BUCKET CYLINDER PROXIMITY SWITCH SYSTEM 794
TROUBLESHOOTING CODE [WRK-7] DEFECTIVE BUCKET CYLINDER FULL STROKE DETECTION SWITCH SYSTEM 796
TROUBLESHOOTING CODE [WRK-8] DEFECTIVE SEMI-AUTOMATIC DIGGING HARD SELECTION SWITCH SYSTEM 797
TROUBLESHOOTING CODE [WRK-9] DEFECTIVE SEMI-AUTOMATIC DIGGING SOFT SELECTION SWITCH SYSTEM 798
TROUBLESHOOTING CODE [WRK-10] DEFECTIVE JOYSTICK ON/OFF SWITCH SYSTEM 800
TROUBLESHOOTING CODE [WRK-11] DEFECTIVE JOYSTICK STEERING SPEED HI/LO SWITCH SYSTEM 802
TROUBLESHOOTING CODE [WRK-12] DEFECTIVE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM 803
TROUBLESHOOTING CODE [WRK-13] HOT SHORT-CIRCUITED LIFT ARM RAISE MAGNET DETENT OUTPUT SYSTEM 804
TROUBLESHOOTING CODE [WRK-14] HOT SHORT-CIRCUITED LIFT ARM FLOATING MAGNET DETENT OUTPUT SYSTEM 805
TROUBLESHOOTING CODE [WRK-15] HOT SHORT-CIRCUITED BUCKET TILT MAGNET DETENT OUTPUT SYSTEM 806
TROUBLESHOOTING CODE [WRK-16] HOT SHORT-CIRCUITED WORK EQUIPMENT NEUTRAL LOCK SOLENOID OUTPUT SYSTEM 807
TROUBLESHOOTING CODE [WRK-17] HOT SHORT-CIRCUITED LIFT ARM RAISE EPC SOLENOID SYSTEM 808
TROUBLESHOOTING CODE [WRK-18] HOT SHORT-CIRCUITED LIFT ARM LOWER EPC SOLENOID SYSTEM 809
TROUBLESHOOTING CODE [WRK-19] HOT SHORT-CIRCUITED BUCKET TILT EPC SOLENOID SYSTEM 810
TROUBLESHOOTING CODE [WRK-20] HOT SHORT-CIRCUITED BUCKET DUMP EPC SOLENOID SYSTEM 811
TROUBLESHOOTING CODE [WRK-21] HOT SHORT-CIRCUITED 3 VALVES EXTENSION EPC SOLENOID SYSTEM 812
TROUBLESHOOTING CODE [WRK-22] HOT SHORT-CIRCUITED 3 VALVES RETRACTION EPC SOLENOID SYSTEM 813
TROUBLESHOOTING CODE [WRK-23] HOT SHORT-CIRCUITED JOYSTICK STEERING RIGHT EPC SOLENOID SYSTEM 814
TROUBLESHOOTING CODE [WRK-24] HOT SHORT-CIRCUITED JOYSTICK STEERING LEFT EPC SOLENOID SYSTEM 815
TROUBLESHOOTING CODE [WRK-25] DEFECTIVE BUCKET POSITIONER, LIFT ARM KICK-OUT AND FLOATING HOLDING FUNCTION 816
TROUBLESHOOTING CODE [WRK-26] DEFECTIVE LIFT ARM KICK-OUT FUNCTION AND CANCELLATION 818
TROUBLESHOOTING CODE [WRK-27] DEFECTIVE BUCKET LEVELER FUNCTION AND CANCELLATION 820
TROUBLESHOOTING CODE [WRK-28] DEFECTIVE LIFT ARM FLOATING HOLDING AND CANCELLATION 822
TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE) 823
CONNECTOR TYPES AND MOUNTING LOCATIONS 825
CONNECTOR LAYOUT DRAWING 834
MONITOR SYSTEM DIAGRAM 840
FAILURE CODE [2F00MA] DRAGGING OF PARKING BRAKE 844
FAILURE CODE [2G42ZG] ACCUMULATOR OIL PRESSURE (FRONT CIRCUIT) LOW 846
FAILURE CODE [2G43ZG] ACCUMULATOR OIL PRESSURE (REAR BRAKE CIRCUIT) LOW 847
FAILURE CODE [AA1ANX] AIR CLEANER 1 CLOGGED 848
FAILURE CODE [AB00L6] DEFECTIVE BATTERY CHARGING CIRCUIT (ALTERNATOR TERMINAL R SIGNAL DETECTED WHEN ENGINE STOPPED 850
FAILURE CODE [AB00MA] DEFECTIVE BATTERY CHARGING CIRCUIT (NO ALTERNATOR TERMINAL R SIGNAL DETECTED, DETECTION FAILURE) 851
FAILURE CODE [B@BAZG] ENGINE OIL PRESSURE LOW 852
FAILURE CODE [B@BAZK] ENGINE OIL LEVEL LOW 853
FAILURE CODE [B@BCNS] ENGINE WATER TEMPERATURE OVERHEATING 854
FAILURE CODE [B@BCZK] ALARM INDICATING LOW COOLANT LEVEL 855
FAILURE CODE [B@HANS] HYDRAULIC OIL TEMPERATURE OVERHEATING 856
FAILURE CODE [B@CENS] TORQUE CONVERTER OIL TEMPERATURE OVERHEATING 857
FAILURE CODE [D182KZ] THE PREHEATER RELAY COIL IS DISCONNECTED OR SHIRT-CIRCUITED 858
FAILURE CODE [D5ZHL6] STARTING SWITCH C (IGN”C”) INPUT FAILURE 860
FAILURE CODE [DA80L4] AUTO GREASE INPUT FAILURE 861
FAILURE CODE [DAF3KK] SW POWER SUPPLY (FOR OPERATION) = ON AND NSW POWER SUPPLY (FOR MEMORY) IS OFF 862
FAILURE CODE [DAF5KP] 5V POWER SUPPLY OUTPUT FAILURE 864
FAILURE CODE [DAF6KP] 24V POWER SUPPLY OUTPUT FAILURE 866
FAILURE CODE [DAFBKM] WRONG INFORMATION ON MODEL SELECTION 868
FAILURE CODE [DAFSKQ] WRONG INFORMATION ON METER DISPLAY SELECTION 869
FAILURE CODE [DAQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND TRANSMISSION CONTROLLER) 870
FAILURE CODE [DBQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) 872
FAILURE CODE [DB9SKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) 873
FAILURE CODE [DD15LD] MONITOR PANEL MODE SELECTOR SWITCH 1 (PANEL SW1) INPUT ERROR 874
FAILURE CODE [DD16LD] MONITOR PANEL MODE SELECTOR SWITCH 1 (PANEL SW2) INPUT ERROR 875
FAILURE CODE [DD17LD] THE MONITOR PANEL MODE SELECTOR SWITCH 2 (PANEL SW3) INPUT CIRCUIT REMAINS CLOSED FOR MORE THAN ONE MINUTE 876
FAILURE CODE [DD18LD] MONITOR PANEL MODE SELECTOR SWITCH 2 (PANEL SW4) INPUT ERROR 877
FAILURE CODE [DD1CLD] SUB-TOTAL SWITCH FAILURE 878
FAILURE CODE [DDS5L6] DECREASED STEERING OIL PRESSURE 880
FAILURE CODE [DDY0LD] CANCEL SWITCH FAILURE 882
FAILURE CODE [DGE2KX] ENGINE WATER TEMPERATURE SENSOR SYSTEM FAILURE 884
FAILURE CODE [DGE3L6] ABNORMAL CONNECTION OF ENGINE WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM 885
FAILURE CODE [DGH2KX] HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM FAILURE 886
FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM FAILURE 887
FAILURE CODE [DHE4L6] ENGINE OIL PRESSURE SENSOR SYSTEM FAILURE 888
FAILURE CODE [DHPCKX] BOTTOM PRESSURE SENSOR FAILURE 890
FAILURE CODE [DHPDKX] HEAD PRESSURE SENSOR FAILURE 892
FAILURE CODE [DKA0KX] LIFT ARM ANGLE SENSOR FAILURE 894
FAILURE CODE [DV00KB] SHORT-CIRCUITED ALARM BUZZER OUTPUT SYSTEM 895
FAILURE CODE [DY30ME] THE EMERGENCY STEERING REMAINS ACTUATED FOR MORE THAN ONE MINUTE 896
TROUBLESHOOTING CODE [MON-1] THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT UP WHEN THE PARKING BRAKE SWITCH IS TURNED ON (THE PARKING BRAKE INDICATOR SWITCH CIRCUIT SUFFERS A GROUND FAULT) 898
TROUBLESHOOTING CODE [MON-2] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (FRONT CIRCUIT) 900
TROUBLESHOOTING CODE [MON-3] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (REAR CIRCUIT) 901
TROUBLESHOOTING CODE [MON-4] THE AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT ON 902
TROUBLESHOOTING CODE [MON-5] THE ENGINE HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON 904
TROUBLESHOOTING CODE [MON-6] THE ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT ON 905
TROUBLESHOOTING CODE [MON-7] THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON 906
TROUBLESHOOTING CODE [MON-8] THE RADIATOR WATER VOLUME CAUTION LAMP DOES NOT LIGHT ON 907
TROUBLESHOOTING CODE [MON-9] THE HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON 908
TROUBLESHOOTING CODE [MON-10] THE TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON 909
TROUBLESHOOTING CODE [MON-11] THE STEERING HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON 910
TROUBLESHOOTING CODE [MON-12] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW1) 911
TROUBLESHOOTING CODE [MON-13] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW2) 912
TROUBLESHOOTING CODE [MON-14] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW3) 913
TROUBLESHOOTING CODE [MON-15] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW4) 914
TROUBLESHOOTING CODE [MON-16] DEFECTIVE SUBTOTAL SWITCH 915
TROUBLESHOOTING CODE [MON-17] DEFECTIVE CANCEL SWITCH 916
TROUBLESHOOTING CODE [MON-18] DEFECTIVE BOTTOM PRESSURE SENSOR (HOT SHORT FAULT) 917
TROUBLESHOOTING CODE [MON-19] DEFECTIVE HEAD SENSOR 918
TROUBLESHOOTING CODE [MON-20] THE ALARM BUZZER DOES NOT SOUND OR STOP (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN BUZZER OUTPUT SYSTEM) 919
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 921
H-1 THE MACHINE DOES NOT START 922
H-2 THE LOCK-UP CLUTCH IS NOT RELEASED (THE ENGINE STOPS) (WHEN THE LOCK-UP CLUTCH IS PROVIDED) 924
H-3 925
a THE TRAVEL SPEED IS SLOW, THE THRUSTING FORCE IS WEAK, THE UPHILL TRAVELING POWER IS WEAK, AND THE GEAR IS NOT SHIFTED 925
b THE TORQUE CONVERTER LOCK-UP CLUTCH IS NOT LET IN (IF THE LOCK-UP CLUTCH IS EQUIPPED) 927
H-4 SHOCKS ARE LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR 928
H-5 TIME LAG IS LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR 930
H-6 THE TORQUE CONVERTER OIL TEMPERATURE IS HIGH 932
H-7 THE STEERING WHEEL DOES NOT TURN 933
H-8 THE STEERING WHEEL IS HEAVY 934
H-9 THE STEERING WHEEL FLUCTUATES OR IS STRONGLY SHOCKED 935
H-10 THE MACHINE STEERS TO ONE SIDE WHEN STAVELING 935
H-11 THE RIGHT AND LEFT SWING RADII ARE DIFFERENT 935
H-12 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL 936
H-13 THE BRAKE IS NOT RELEASED OR IS DRAGGED 937
H-14 THE BRAKE IS NOT RELEASED OR DRAGGED 938
H-15 THE LIFT ARM DOES NOT RISE 939
H-16 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT 940
H-17 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT 941
H-18 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR) 941
H-19 HYDRAULIC DRIFTS OF THE BOOM OCCUR OFTEN 941
H-20 THE LIFT ARM WOBBLES DURING OPERATION 941
H-21 WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “RAISE”, THE LIFT ARM FALLS TEMPORARILY 942
H-22 THE BUCKET DOES NOT TILT BACK 943
H-23 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT 944
H-24 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILTING-BACK 945
H-25 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET 945
H-26 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN 945
H-27 THE BUCKET WOBBLES DURING TRAVEL CARGO (THE WORK EQUIPMENT VALVE IS SET TO “HOLD”) 946
H-28 WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “TILT”, THE BUCKET FALLS TEMPORARILY 946
H-29 THE CONTROL LEVERS OF LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY 947
H-30 E C S S DOES NOT WORK, AND THERE IS PITCING AND BOUNCING 948
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 949
CONNECTOR TYPES AND MOUNTING LOCATIONS 951
CONNECTOR LAYOUT DRAWING 960
ELECTRICAL SYSTEM DIAGRAM 966
TROUBLESHOOTING CODE [E-1-a] (THE ENGINE DOES NOT START (STARTING SYSTEM)) 968
TROUBLESHOOTING CODE [E-1-b] (THE ENGINE DOES NOT START (ENGINE STOP SOLENOID SYSTEM)) 972
TROUBLESHOOTING CODE [E-2] (THE ENGINE DOES NOT STOP) 974
TROUBLESHOOTING CODE [E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT) 976
TROUBLESHOOTING CODE [E-4] (THE ENGINE POWER MODES CANNOT BE SELECTED) 978
TROUBLESHOOTING CODE [E-5] (THE FRONT WIPER DOES NOT FUNCTION) 980
TROUBLESHOOTING CODE [E-6] (THE REAR WIPER DOES NOT FUNCTION) 983
TROUBLESHOOTING CODE [E-7] (THE SIDE WIPER DOES NOT FUNCTION (IF EQUIPPED)) 984
TROUBLESHOOTING CODE [E-8] (THE WIND WASHER DOES NOT FUNCTION) 985
TROUBLESHOOTING CODE [E-9] (THE HEADLAMP (LO BEAM) DOES NOT LIGHT ON) 988
TROUBLESHOOTING CODE [E-10] (THE HEADLAMP (HI BEAM) DOES NOT FUNCTION) 991
TROUBLESHOOTING CODE [E-11] (THE CLEARANCE LAMP DOES NOT LIGHT ON (SMALL LAMP)) 993
TROUBLESHOOTING CODE [E-12] (THE TURN SIGNAL DOES NOT BLINK) 994
TROUBLESHOOTING CODE [E-13] (THE HORN DOES NOT SOUND) 996
TROUBLESHOOTING CODE [E-14] (THE AIR CONDITIONER DOES NOT WORK OR DOES NOT STOP) 998
TROUBLESHOOTING OF ENGINE (S MODE) 1001
METHOD OF USING TROUBLESHOOTING CHARTS 1002
S-1 STARTING PREFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 1006
S-2 ENGINE DOES NOT START 1007
(1) ENGINE DOES NOT TURN 1007
(2) ENGINE TURN BUT NO EXHAUST SMOKE COMES OUT (FUEL IS BEING INJECTED) 1008
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 1009
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 1010
S-4 ENGINE STOPS DURING OPERATIONS 1011
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 1012
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 1013
S-7 EXHAUST SMOKE IS BLACK (INCOMPLATE COMBUSTION) 1014
S-8 OIL CONSUMPTION IS ESCESSIVE (OR EXHAUST SMOKE IS BLUE) 1015
S-9 OIL BECOMES CONTAMINATED QUICKLY 1016
S-10 FUEL CONSUMPTION IS EXCESSIVE 1017
S-11 OIL IS IN COOLING COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN 1018
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 1019
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 1020
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 1021
S-15 ABNORMAL NOISE IS MADE 1022
S-16 VIBRATION IS EXCESSIVE 1023
30 DISASSEMBLY AND ASSEMBLY 1025
METHOD OF USING MANUAL 1026
PRECAUTIONS WHEN CARRYING OUT OPERATION 1028
SPECIAL TOOL LIST 1031
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY 1043
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY 1047
REMOVAL AND INSTALLATION OF RADIATOR AND FAN MOTOR ASSEMBLY 1052
REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY 1054
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP 1054
REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY 1057
REMOVAL AND INSTALLATION OF FAN AND MOTOR ASSEMBLY 1059
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY 1060
REMOVAL AND INSTALLATION OF PARKING BRAKE DISC PLATE 1062
REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 1065
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY 1069
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH PACK ASSEMBLY 1081
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY 1096
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (STANDARD SPECIFICATION) 1104
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (LOCK-UP SPECIFICATION) 1108
REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY 1114
REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY 1117
DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY 1118
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY 1126
REMOVAL AND INSTALLATION OF CENTER HINGE PIN 1145
REMOVAL AND INSTALLATION OF CAB ASSEMBLY 1152
REMOVAL AND INSTALLATION OF CAB AND FLOOR FRAME ASSEMBLY 1153
REMOVAL AND INSTALLATION OF TRANSMISSION OF OPERATOR’S CAB GLASS (STUCK GLASS) 1156
REMOVAL AND INSTALLATION OF TRANSMISSION, WORK EQUIPMENT, AND PPC PUMP ASSEMBLY 1164
REMOVAL AND INSTALLATION OF STEERING, SWITCHING, AND FAN PUMP ASSEMBLY 1165
REMOVAL AND INSTALLATION OF STEERING DEMAND VALVE ASSEMBLY 1166
REMOVAL AND INSTALLATION OF STEERING VALVE OIL SEAL 1167
REMOVAL AND INSTALLATION OF E C S S VALVE ASSEMBLY 1169
REMOVAL AND INSTALLATION OF WORK EQUIPMENT VALVE ASSEMBLY 1170
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY (STEERING, LIFT, AND BUCKET CYLINDER ASSEMBLY) 1172
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY 1180
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY 1182
REMOVAL AND INSTALLATION OF COUNTER WEIGHT 1186
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY 1187
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY 1190
DISASSEMBLY, ASSEMBLY OF OPERATOR’S SEAT ASSEMBLY 1191
90 OTHERS 1201
POWER TRAIN OIL CIRCUIT DIAGRAM (WITHOUT TORQUE CONVERTER LOCKUP CLUTCH) 1203
POWER TRAIN OIL CIRCUIT DIAGRAM (WITH TORQUE CONVERTER LOCKUP CLUTCH) 1205
BRAKE OIL CIRCUIT DIAGRAM 1207
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 1209
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (FOR ELECTRIC WORK EQUIPMENT LEVER) 1211
ELECTRICAL CIRCUIT DIAGRAM 1213
1/8 (1/4) 1213
1/8 (2/4) 1215
1/8 (3/4) 1217
1/8 (4/4) 1219
2/8 (1/4) 1221
2/8 (2/4) 1223
2/8 (3/4) 1225
2/8 (4/4) 1227
3/8 1229
4/8 1231
5/8 1233
6/8 1235
7/8 1237
8/8 1239

VIDEO PREVIEW OF THE MANUAL:

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