Komatsu WA470-5 WA480-5 Wheel Loader Shop Manual SEBM024416 – PDF DOWNLOAD

Komatsu WA470-5 WA480-5 Wheel Loader Shop Manual SEBM024416 – PDF DOWNLOAD

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Komatsu WA470-5 WA480-5 Wheel Loader Shop Manual SEBM024416 – PDF DOWNLOAD

Language : English
Pages : 1312
Downloadable : Yes
File Type : PDF
Size: 90.8 MB

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Komatsu WA470-5 WA480-5 Wheel Loader Shop Manual SEBM024416 – PDF DOWNLOAD

MACHINE MODEL   SERIAL NUMBER
WA480-5                    80001 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 WA470-5 WA480-5 Wheel Loader Shop Manual SEBM024416 – 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
RADIATOR, OIL COOLER 40
ENGINE MOUNT, TRANSMISSION MOUNT 41
POWER TRAIN 42
POWER TRAIN SYSTEM DIAGRAM 43
DRIVE SHAFT 46
TORQUE CONVERTER,TRANSMISSION PIPING 47
TORQUE CONVERTER 48
TRANSMISSION 58
TRANSMISSION CONTROL VALVE 76
AXLE 94
DIFFERENTIAL 98
FINAL DRIVE 110
AXLE MOUNTING,CENTER HINGE PIN 116
STEERING PIPING 120
STEERING COLUMN, ORBIT-ROLL 121
STEERING VALVE 122
ORBIT-ROLL VALVE 138
STOP VALVE 142
STEERING PUMP, SWITCH PUMP 144
EMERGENCY STEERING PUMP (IF EQUIPPED) 146
EMERGENCY STEERING MOTOR (IF EQUIPPED) 147
STEERING CYLINDER 148
JOYSTICK STEERING LEVER (IF EQUIPPED) 150
STEERING LEVER (IF EQUIPPED) 152
STEERING SWITCH VALVE (IF EQUIPPED) 154
BRAKE PIPING 156
BRAKE VALVE 158
CHARGE VALVE 166
ACCUMULATOR (FOR BRAKE) 170
SLACK ADJUSTER 172
BRAKE 174
PARKING BRAKE CONTROL 180
PARKING BRAKE 182
PARKING BRAKE SOLENOID VALVE 184
PARKING BRAKE EMERGENCY RELEASE VALVE 186
HYDRAULIC PIPING 188
WORK EQUIPMENT CONTROL LEVER 192
HYDRAULIC TANK 194
TORQUE CONVERTER CHARGING,WORK EQUIPMENT,AND PPC PUMPS 196
PPC RELIEF VALVE 198
ECSS VALVE (IF EQUIPPED) 200
WORK EQUIPMENT CONTROL VALVE 202
PPC VALVE 222
PPC VALVE (FOR MULTI FUNCTION MONO LEVER) 228
WORK EQUIPMENT CONTROL EPC VALVE (IF EQUIPPED) 234
SHUT OFF VALVE (IF EQUIPPED) 237
COOLING FAN MOTOR 238
COOLING FAN MOTOR DRIVE PUMP 244
WORK EQUIPMENT LINKAGE 252
BUCKET 254
BUCKET POSITIONER, BOOM KICK-OUT 256
WORK EQUIPMENT CYLINDER 262
CAB 264
AIR CONDITIONER (IF EQUIPPED) 265
MACHINE MONITORING SYSTEM 266
MACHINE MONITOR 274
TRANSMISSION CONTROL SYSTEM 344
TRANSMISSION CONTROLLER 372
WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED) 374
WORK EQUIPMENT CONTROLLER (IF EQUIPPED) 390
ELECTRIC TRANSMISSION CONTROL 392
KICK DOWN, HOLD SWITCH 396
ENGINE STARTING CIRCUIT 398
ENGINE STOP CIRCUIT 400
PARKING BRAKE CIRCUIT 402
SENSORS 406
20 TESTING AND ADJUSTING 417
STANDARD VALUE TABLE 418
STAND ARD VALUE TABLE FOR ENGINE 418
STANDARD VALUE TABLE FOR CHASSIS 419
TESTING AND ADJUSTING 427
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 428
MEASURING ENGINE SPEED 430
MEASURING EXHAUST COLOR 432
MEASURING EXHAUST TEMPERATURE 433
ADJUSTING VALVE CLEARANCE 434
MEASURING COMPRESSION PRESSURE 436
MEASURING BLOW-BY PRESSURE 438
MEASURING ENGINE OIL PRESSURE 439
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 440
MEASURING FUEL PRESSURE 440
TESTING LEAKAGE THROUGH PRESSURE LIMITER AND RETURN RATE FROM INJECTOR 442
HANDLING EQUIPMENT IN FUEL SYSTEM 446
RELEASING REMAINING PRESSURE IN FUEL SYSTEM 446
BLEEDING AIR FROM FUEL CIRCUIT 447
REDUCED CYLINDER MODE OPERATION FOR ENGINE 449
CHECKING FOR LEAKAGE IN FUEL SYSTEM 451
ADJUSTING ACCELERATOR PEDAL POTENTIOMETER 452
ADJUSTING ACCELERATOR PEDAL MICROSWITCH 453
ADJUSTING TRANSMISSION SPEED SENSOR 454
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE 455
PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT 459
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS 460
TESTING AND ADJUSTING STEERING CONTROL 462
TESTING AND ADJUSTING STEERING OIL PRESSURE 463
TESTING HYDRAULIC FAN 465
MEASURING BRAKE OIL PRESSURE 466
TESTING WEAR OF WHEEL BRAKE DISC 468
BLEEDING AIR FROM BRAKE CIRCUIT 469
TESTING WEAR OF PARKING BRAKE DISC 470
MANUAL RELEASE METHOD FOR PARKING BRAKE 471
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE 472
TESTING AND ADJUSTING PPC OIL PRESSURE 474
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE 476
TESTING AND ADJUSTING BUCKET POSITIONER 478
TESTING AND ADJUSTING LIFT ARM KICK-OUT 479
CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP 480
ADJUSTING MACHINE MONITOR 481
TESTING AND ADJUSTING LOAD METER 484
BLEEDING AIR 488
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 489
RELEASING REMAINING PRESSURE IN ECSS DAMPER CIRCUIT 489
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT 490
INDICATOR LAMPS OF KOMTRAX TERMINAL 491
PM-CLINIC INSPECTION TABLE 497
TROUBLESHOOTING 499
POINTS TO REMEMBER WHEN TROUBLESHOOTING 500
SEQUENCE OF EVENTS IN TROUBLESHOOTING 501
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 502
CHECKS BEFORE TROUBLESHOOTING 510
SPECIAL FUNCTIONS OF MACHINE MONITOR 512
CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS 549
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 558
T-ADAPTER TABLE 581
CONNECTOR TYPES AND INSTALLATION POSITIONS 585
CONNECTORS LAYOUT DRAWING 594
TROUBLESHOOTING OF ENGINE CONTROL SYSTEM (ENG MODE) 603
ENGINE CONTROL SYSTEM DIAGRAM 604
FAILURE CODE [A000N1] (ENGINE OVERRUN (N1)) IS DISPLAYED 606
FAILURE CODE [AD00L2] (COMMON RAIL IS HIGHER THAN MAXIMUM SET VALUE) IS DISPLAYED 607
FAILURE CODE [AD00MA] (FUNCTION OF COMMON RAIL IS DEFECTIVE) IS DISPLAYED 608
FAILURE CODE [AD10L3] (FUEL SUPPLY PUMP CANNOT BE CONTROLLED) IS DISPLAYED 609
FAILURE CODE [AD10MA] (FUNCTION OF FUEL SUPPLY PUMP IS DEFECTIVE) IS DISPLAYED 613
FAILURE CODE [AD10MB] (FUNCTION OF FUEL SUPPLY PUMP IS LOWERED) IS DISPLAYED 614
FAILURE CODE [AD11KA] (DISCONNECTION IN FUEL SUPPLY PUMP PVC1 SYSTEM) IS DISPLAYED 615
FAILURE CODE [AD11KB] (SHORT CIRCUIT IN FUEL SUPPLY PUMP PVC1 SYSTEM) IS DISPLAYED 616
FAILURE CODE [AD51KA] (DISCONNECTION IS FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED 617
FAILURE CODE [AD51KB] (SHORT CIRCUIT IN FUEL SUPPLY PUMP PVC2 SYSTEM) IS DISPLAYED 618
FAILURE CODE [ADA1KA] (DISCONNECTION IN NO 1 INJECTOR SOLENOID VALVE SYSTEM) IS DISPLAYED) 619
FAILURE CODE [ADAZKB] (SHORT CIRCUIT IN NO 1,2,3 INJECTOR SOLENOID VALVE SYSTEM) IS DISPLAYED 620
FAILURE CODE [ADB1KA] (DISCONNECTION IN NO 2 INJECTOR SOLENOID VALVE SYSTEM) IS DISPLAYED 622
FAILURE CODE [ADC1KA] (DISCONNECTION IN NO 3 INJECTOR SOLENOID VALVE SYSTEM) IS DISPLAYED 623
FAILURE CODE [ADD1KA] (DISCONNECTION IN NO 4 INJECTOR SOLENOID VALVE SYSTEM) IS DISPLAYED 624
FAILURE CODE [ADDZKB] (SHORT CIRCUIT IN NO 4,5,6 INJECTOR SOLENOID VALVE SYSTEM) IS DISPLAYED 626
FAILURE CODE [ADE1KA] (DISCONNECTION IN NO 5 INJECTOR SOLENOID VALVE SYSTEM) IS DISPLAYED 628
FAILURE CODE [ADF1KA] (DISCONNECTION IN NO 6 INJECTOR SOLENOID VALVE SYSTEM) IS DISPLAYED 629
FAILURE CODE [D182KZ] (DISCONNECTION OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL) ID DISPLAYED 630
FAILURE CODE [D1D0KB] (SHORT CIRCUIT IN VOLTAGE LOAD POWER SUPPLY OF ENGINE CONTROLLER POWER SUPPLY (SW) CIRCUIT) IS DISPLAYED 632
FAILURE CODE [DB20KT] (TROUBLE IN CONTROLLER) IS DISPLAYED 634
FAILURE CODE [DB22KK] (TROUBLE IN POWER SUPPLY OF ENGINE CONTROLLER LOAD POWER SUPPLY (SW) 1) IS DISPLAYED 636
FAILURE CODE [DB29KQ] (NONCONFORMANCE OF MODEL SELECTION SIGNALS IN ENGINE CONTROLLER CONNECTING WIRING HARNESS) IS DISPLAYED 638
FAILURE CODE [DB2AMA] (FUNCTION OF Q ADJUSTMENT SWITCH OF ENGINE CONTROLLER IS DEFECTIVE) IS DISPLAYED 640
FAILURE CODE [DD11KB] (TROUBLE IN INPUT OF STARTING SWITCH C (IGN C)) IS DISPLAYED 642
FAILURE CODE [DGE3L6] (TROUBLE IN WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM) IS DISPLAYED 644
FAILURE CODE [DGE4KX] (TROUBLE IN FUEL TEMPERATURE SENSOR SYSTEM) ID DISPLAYED 645
FAILURE CODE [DH30KX] (TROUBLE IN BOOST PRESSURE SENSOR SYSTEM) ID DISPLAYED 646
FAILURE CODE [DH40KX] (TROUBLE IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM) IS DISPLAYED 647
FAILURE CODE [DK10KX] (TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM) IS DISPLAYED 648
FAILURE CODE [DLE3LC] (TROUBLE IN ENGINE NE SPEED SENSOR SYSTEM) IS DISPLAYED 649
FAILURE CODE [DLH1LC] (TROUBLE IN ENGINE G SPEED SYSTEM) IS DISPLAYED 650
TROUBLESHOOTING CODE [ENG-1] (ENGINE DOED NOT START) IS DISPLAYED 651
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (TM MODE) 657
TRANSMISSION CONTROL SYSTEM DIAGRAM 660
FAILURE CODE [1500L1] (DOUBLE ENGAGEMENT DETECTED) IS DISPLAYED 663
FAILURE CODE [15SAL1] (F_ECMV F_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 664
FAILURE CODE [15SALH] (F_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 665
FAILURE CODE [15SBL1] (R_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 666
FAILURE CODE [15SBLH] (R_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 667
FAILURE CODE [15SEL1] (1ST_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 668
FAILURE CODE [15SELH] (1ST_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 669
FAILURE CODE [15SFL1] (2ND_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 670
FAILURE CODE [15SFLH] (2ND_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 671
FAILURE CODE [15SGL1] (3RD_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 672
FAILURE CODE [15SGLH] (3RD_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 673
FAILURE CODE [15SHL1] (4TH_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 674
FAILURE CODE [15SHLH] (4TH_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 675
FAILURE CODE [15SJL1] (LOCKUP_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 676
FAILURE CODE [15SJLH] (LOCKUP_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 677
FAILURE CODE [989F00] (TRANSMISSION PROTECTION CAUTION) IS DISPLAYED 678
FAILURE CODE [B@C7NS] (REAR BRAKE COOLING OIL OVERHEAT) IS DISPLAYED 680
FAILURE CODE [D150KA] (EMERGENCY STEERING RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 681
FAILURE CODE [D150KB] (EMERGENCY STEERING RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 682
FAILURE CODE [D160KA] (BACKUP LAMP RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 683
FAILURE CODE [D160KB] (BACKUP LAMP RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 684
FAILURE CODE [D191KA] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 686
FAILURE CODE [D191KB] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 688
FAILURE CODE [D192KA] (TRAVEL DAMPER RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 690
FAILURE CODE [D192KB] (TRAVEL DAMPER RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 691
FAILURE CODE [DAQ0KK] (CONTROLLER POWER SUPPLY VOLTAGE LOWERED) IS DISPLAYED 692
FAILURE CODE [DAQ2KK] (DEFECTIVE SOLENOID POWER SUPPLY SYSTEM) IS DISPLAYED 693
FAILURE CODE [DAQ9KQ] (MODEL SELECTION SIGNAL MISMATCH) IS DISPLAYED 694
FAILURE CODE [DDK3KA] (RIGHT FNR SWITCH SIGNAL NOT INPUT) IS DISPLAYED 696
FAILURE CODE [DDK3KB] (MULTIPLE RIGHT FNR SWITCH OR MULTI FUNCTION MONO LEVER FNR SWITCH SIGNAL INPUT) IS DISPLAYED 698
FAILURE CODE [DDK6KA] (FORWARD-REVERSE LEVER SIGNAL NOT INPUT) IS DISPLAYED 700
FAILURE CODE [DDK6KB] (MULTIPLE FORWARD-REVERSE LEVER SIGNAL INPUT) IS DISPLAYED 702
FAILURE CODE [DDS5KA] (STEERING PRESSURE SWITCH DISCONNECTED) IS DISPLAYED 704
FAILURE CODE [DDS5KB] (STEERING PRESSURE SWITCH GROUNDED) IS DISPLAYED 705
FAILURE CODE [DDT0L4] (MANUAL/AUTO-SHIFT SELECTOR SWITCH SELECTION FAILURE) IS DISPLAYED 706
FAILURE CODE [DDT4LD] (GROUND FAULT OF TRANSMISSION CUT-OFF SETTING SWITCH) IS DISPLAYED 708
FAILURE CODE [DDW9LD] (GROUND FAULT OF KICKDOWN SWITCH SYSTEM) IS DISPLAYED 709
FAILURE CODE [DDWLLD] (GROUND FAULT OF HOLD SWITCH SYSTEM) IS DISPLAYED 712
FAILURE CODE [DF10KA] (NO INPUT OF GEAR SHIFT LEVER SIGNAL) IS DISPLAYED 714
FAILURE CODE [DF10KB] (INPUT OF MULTIPLE GEAR SHIFT LEVER SIGNALS) IS DISPLAYED 716
FAILURE CODE [DGF1KX] (TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM FAILURE) IS DISPLAYED 718
FAILURE CODE [DGR2KA] (REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM DISCONNECTION) IS DISPLAYED 719
FAILURE CODE [DGR2KB] (GROUND FAULT OF REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED 720
FAILURE CODE [DHT1KX] (TRANSMISSION CUT-OFF (LEFT BRAKE PRESSURE SENSOR) SIGNAL DISCONTINUITY) IS DISPLAYED 721
FAILURE CODE [DLE2KA] (ENGINE REVOLUTION SENSOR SYSTEM DISCONTINUITY) IS DISPLAYED 722
FAILURE CODE [DLE2LC] (ENGINE REVOLUTION SENSOR FAILURE) IS DISPLAYED 723
FAILURE CODE [DLT3KA] (SPEED SENSOR SYSTEM DISCONTINUITY (TRANSMISSION REVOLUTION SENSOR FAILURE)) IS DISPLAYED 724
FAILURE CODE [DT20KB] (GROUND FAULT OF BUILT-IN INDICATOR LAMP SYSTEM OF TRANSMISSION CUT-OFF SWITCH) IS DISPLAYED 725
FAILURE CODE [DW7BKA] (FAN PUMP REVERSE SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 726
FAILURE CODE [DW7BKB] (FAN PUMP REVERSE SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 727
FAILURE CODE [DW7CKA] (SWITCH PUMP CUT-OFF RELAY DISCONTINUITY) IS DISPLAYED 728
FAILURE CODE [DW7CKB] (SWITCH PUMP CUT-OFF RELAY GROUND FAULT) IS DISPLAYED 729
FAILURE CODE [DX16KA] (FAN PUMP EPC SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 730
FAILURE CODE [DX16KB] (FAN PUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 731
FAILURE CODE [DXH1KA] (LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 732
FAILURE CODE [DXH1KB] (LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 733
FAILURE CODE [DXH4KA] (1ST_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 734
FAILURE CODE [DXH4KB] (1ST_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 735
FAILURE CODE [DXH5KA] (2ND_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 736
FAILURE CODE [DXH5KB] (2ND_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 737
FAILURE CODE [DXH6KA] (3RD_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 738
FAILURE CODE [DXH6KB] (3RD_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 739
FAILURE CODE [DXH7KA] (R_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 740
FAILURE CODE [DXH7KB] (3RD_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 741
FAILURE CODE [DXH8KA] (F_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 742
FAILURE CODE [DXH8KB] (F_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 743
FAILURE CODE [DXHHKA] (4TH_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 744
FAILURE CODE [DXHHKB] (4TH_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED 745
FAILURE CODE [DY30MA] (MOTOR-DRIVEN EMERGENCY STEERING PUMP ERROR (MALFUNCTION IN MANUAL MODE)) 746
FAILURE CODE [DY30MC] (MOTOR-DRIVEN EMERGENCY STEERING PUMP ERROR (MALFUNCTION IN MANUAL MODE)) 748
TROUBLESHOOTING CODE [TM-1] DISCONTINUITY OR HOT SHORT-CIRCUITING OF KICKDOWN SWITCH SYSTEM 750
TROUBLESHOOTING CODE [TM-2] HOLD SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING (NO HOLD CONTROL PERFORMED BY PRESSING HOLD SWITCH) 752
TROUBLESHOOTING CODE [TM-3] TORQUE CONVERTER LOCK-UP SWITCH SYSTEM FAILURE (NO LOCK-UP PERFORMED OR NO LOCK-UP CANCELLATION PERFORMED) 754
TROUBLESHOOTING CODE [TM-4] NEUTRALIZER SIGNAL (PARKING BRAKE SWITCH SIGNAL) SYSTEM FAILURE 756
TROUBLESHOOTING CODE [TM-5] EMERGENCY STEERING SWITCH (MOTOR-DRIVEN EMERGENCY STEERING OPERATION SWITCH) SIGNAL SYSTEM FAILURE 758
TROUBLESHOOTING CODE [TM-6] TRANSMISSION CUT-OFF SWITCH SYSTEM DISCONTINUITY OR GROUND FAULT 760
TROUBLESHOOTING CODE [TM-7] TRANSMISSION CUT-OFF SETTING SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING 761
TROUBLESHOOTING CODE [TM-8] TRANSMISSION CUT-OFF (LEFT BRAKE SENSOR) SIGNAL SHORT-CIRCUITING 762
TROUBLESHOOTING CODE [TM-9-a] JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH SYSTEM FAILURE (DISCONTINUITY OR GROUND FAULT) 763
TROUBLESHOOTING CODE [TM-9-b] (FNR SWITCH MODE CHANGE OVER SWITCH SYSTEM FAILURE) 764
TROUBLESHOOTING CODE [TM-10] (STARTING SWITCH “C” (IGN_C) SIGNAL SYSTEM FAILURE) 766
TROUBLESHOOTING CODE [TM-11] (JOYSTICK ON/OFF CHANGE OVER SWITCH SYSTEM FAILURE) 768
TROUBLESHOOTING CODE [TM-12] (ENGINE POWER MODE SWITCH DISCONTINUITY OR GROUND FAULT) 770
TROUBLESHOOTING CODE [TM-13] (TRAVEL DAMPER NO/OFF SWITCH DISCONTINUITY OR GROUND FAULT) 771
TROUBLESHOOTING CODE [TM-14] (HYDRAULIC FAN REVERSE SWITCH SIGNAL SYSTEM HOT SHORT-CIRCUITING OR DISCONTINUITY) 772
TROUBLESHOOTING CODE [TM-15] (MOTOR-DRIVEN EMERGENCY STEERING RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING) 774
TROUBLESHOOTING CODE [TM-16] (TRAVEL DAMPER RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING) 775
TROUBLESHOOTING CODE [TM-17] (SWITCH PUMP CUT-OFF RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING) 776
TROUBLESHOOTING CODE [TM-18] (BACK LAMP RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING) 777
TROUBLESHOOTING CODE [TM-19] (NEUTRAL OUTPUT SYSTEM HOT SHORT-CIRCUITING) 778
TROUBLESHOOTING CODE [TM-20] (F ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING) 779
TROUBLESHOOTING CODE [TM-21] (R ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING) 780
TROUBLESHOOTING CODE [TM-22] (1ST ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING) 781
TROUBLESHOOTING CODE [TM-23] (2ND ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING) 782
TROUBLESHOOTING CODE [TM-24] (3RD ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING) 783
TROUBLESHOOTING CODE [TM-25] (4TH ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING) 784
TROUBLESHOOTING CODE [TM-26] (LOCK-UP ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING) 785
TROUBLESHOOTING CODE [TM-27] (FAN PUMP EPC SOLENOID SYSTEM HOT SHORT-CIRCUITING) 786
TROUBLESHOOTING CODE [TM-28] (FAN REVERSE SOLENOID SYSTEM HOT SHORT-CIRCUITING) 787
TROUBLESHOOTING CODE [TM-29] (SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM FAILURE) 788
TROUBLESHOOTING CODE [TM-30] (ECSS SOLENOID SYSTEM DISCONTINUITY OR GROUND FAULT) 789
TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WRK MODE) 791
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 794
FAILURE CODE [D193KA] (DEFECTIVE JOYSTICK STEERING CUT RELAY SYSTEM (MAIN SYSTEM DISCONNECTED)) IS DISPLAYED 797
FAILURE CODE [D193KB] (DEFECTIVE JOYSTICK SOLENOID CUT RELAY SYSTEM (GROUND FAULT)) IS DISPLAYED 798
FAILURE CODE [DB90KK] (LOWERING VOLTAGE OF WORK EQUIPMENT CONTROLLER POWER SUPPLY) IS DISPLAYED 799
FAILURE CODE [DB92KK] (DEFECTIVE SOLENOID ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED 800
FAILURE CODE [DB95KX] (DEFECTIVE 5V ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED 802
FAILURE CODE [DD1ALD] (DEFECTIVE REMOTE POSITIONER UP SET SWITCH (GROUND FAULT)) IS DISPLAYED 804
FAILURE CODE [DD1BLD] (DEFECTIVE REMOTE POSITIONER DOWN SET SWITCH (GROUND FAULT)) IS DISPLAYED 805
FAILURE CODE [DFAOKM] (DEFECTIVE NEUTRAL CAUTION FOR JOYSTICK WORK EQUIPMENT LEVER) IS DISPLAYED 806
FAILURE CODE [DK59KA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 807
FAILURE CODE [DK59KY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORT CIRCUIT)) IS DISPLAYED 808
FAILURE CODE [DK59L8] (DEFECTIVE LIFT ARM EPC POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED 809
FAILURE CODE [DK5AKA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OF MAIN) (DISCONNECTION, GROUND OF SUB)) IS DISPLAYED 810
FAILURE CODE [DK5AKY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED 811
FAILURE CODE [DK5BKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 812
FAILURE CODE [DK5BKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN CIUCUIT SHORTED)) IS DISPLAYED 813
FAILURE CODE [DK5BL8] (DEFECTIVE INPUT SIGNAL FOR BUCKET EPC LEVER POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB CIRCUIT)) IS DISPLAYED 814
FAILURE CODE [DK5CKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SUB CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 815
FAILURE CODE [DK5CKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB CIRCUIT)) IS DISPLAYED 816
FAILURE CODE [DK5DKA] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 817
FAILURE CODE [DK5DKY] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORTED)) IS DISPLAYED 818
FAILURE CODE [DK5DL8] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DISPLACEMENT OF MAIN AND SUB CIRCUIT)) IS DISPLAYED 819
FAILURE CODE [DK5EKA] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SUB CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 820
FAILURE CODE [DK5EKY] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB CIRCUIT)) IS DISPLAYED 821
FAILURE CODE [DK5FKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 822
FAILURE CODE [DK5FKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORTED)) IS DISPLAYED 823
FAILURE CODE [DK5FKM] (JOYSTICK STEERING EPC LEVER NEUTRAL SYSTEM) IS DISPLAYED 824
FAILURE CODE [DK5FL8] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (DEVIATION OF POSITIONAL SIGNALS OF MAIN AND SUB CIRCUITS)) IS DISPLAYED 825
FAILURE CODE [DK5GKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUND FAULT OF SUB CIRCUIT)) IS DISPLAYED 826
FAILURE CODE [DK5GKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (SUB CIRCUIT SHORT CIRCUIT)) IS DISPLAYED 827
FAILURE CODE [DKAOKA] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (OUTSIDE OF SIGNAL VOLTAGE AREA: DISCONNECTION OR GROUND FAULT)) IS DISPLAYED 828
FAILURE CODE [DKAOKY] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (SHORT CIRCUIT)) IS DISPLAYED 829
FAILURE CODE [DLE2LC] (DEFECTIVE ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 830
FAILURE CODE [DLT3LC] (DEFECTIVE TRANSMISSION OUTPUT AXIS SPEED SENSOR SYSTEM (DISCONNECTED)) IS DISPLAYED 831
FAILURE CODE [DUM1KB] (REMOTE POSITIONER RAISE LAMP SYSTEM GROUND FAULT) IS DISPLAYED 832
FAILURE CODE [DUM2KB] (REMOTE POSITIONER LOWER LAMP SYSTEM GROUND FAULT) IS DISPLAYED 833
FAILURE CODE [DW4PKA] (DISCONNECTED LIFT ARM RAISE EPC SOLENOID SYSTEM) IS DISPLAYED 834
FAILURE CODE [DW4PKB] (LIFT ARM RAISE EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 835
FAILURE CODE [DW4QKA] (DISCONNECTED LIFT ARM LOWER EPC SOLENOID SYSTEM) IS DISPLAYED 836
FAILURE CODE [DW4QKB] (LIFT ARM LOWER EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 837
FAILURE CODE [DW4RKA] (DISCONNECTED BUCKET TILT EPC SOLENOID SYSTEM) IS DISPLAYED 838
FAILURE CODE [DW4RKB] (BUCKET TILT EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 839
FAILURE CODE [DW4SKA] (BUCKET DUMP EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 840
FAILURE CODE [DW4SKB] (BUCKET DUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 841
FAILURE CODE [DWM1KA] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 842
FAILURE CODE [DWM1KB] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 843
FAILURE CODE [DWN6KA] (LIFT ARM RAISE MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED 844
FAILURE CODE [DWN6KB] (LIFT ARM RAISE MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED 845
FAILURE CODE [DWN7KA] (LIFT ARM FLOATING MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED 846
FAILURE CODE [DWN7KB] (LIFT ARM FLOATING MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED 847
FAILURE CODE [DWN8KA] (BUCKET TILT MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED 848
FAILURE CODE [DWN8KB] (BUCKET TILT MAGNET DETENT SYSTEM FAILURE (POWER SUPPLY SYSTEM GROUND FAULT)) IS DISPLAYED 849
FAILURE CODE [DXHJKA] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 850
FAILURE CODE [DXHJKB] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 851
FAILURE CODE [DXHKKA] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 852
FAILURE CODE [DXHKKB] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 853
FAILURE CODE [DXHLKA] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 854
FAILURE CODE [DXHLKB] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 855
FAILURE CODE [DXHMKA] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 856
FAILURE CODE [DXHMKB] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 857
TROUBLESHOOTING CODE [WRK-1] DEFECTIVE LIFT ARM LOCK SWITCH SYSTEM 858
TROUBLESHOOTING CODE [WRK-2] DEFECTIVE REMOTE POSITIONER RAISE SETTING SWITCH SYSTEM 859
TROUBLESHOOTING CODE [WRK-3] DEFECTIVE REMOTE POSITIONER LOWER SETTING SWITCH SYSTEM 860
TROUBLESHOOTING CODE [WRK-4] DEFECTIVE REMOTE POSITIONER RAISE SELECTION SWITCH SYSTEM 862
TROUBLESHOOTING CODE [WRK-5] DEFECTIVE REMOTE POSITIONER LOWER ON/OFF SWITCH SYSTEM 864
TROUBLESHOOTING CODE [WRK-6] DEFECTIVE BUCKET CYLINDER PROXIMITY SWITCH SYSTEM 866
TROUBLESHOOTING CODE [WRK-7] DEFECTIVE BUCKET CYLINDER FULL STROKE DETECTION SYSTEM 868
TROUBLESHOOTING CODE [WRK-8] DEFECTIVE SEMI-AUTOMATIC DIGGING HARDWARE SELECTION SWITCH SYSTEM 869
TROUBLESHOOTING CODE [WRK-9] DEFECTIVE SEMI-AUTOMATIC DIGGING SOFTWARE SELECTION SWITCH SYSTEM 870
TROUBLESHOOTING CODE [WRK-10] DEFECTIVE JOYSTICK ON/OFF SWITCH SYSTEM 872
TROUBLESHOOTING CODE [WRK-11] DEFECTIVE JOYSTICK STEERING SPEED HI/LO SWITCH SYSTEM 874
TROUBLESHOOTING CODE [WRK-12] DEFECTIVE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM 875
TROUBLESHOOTING CODE [WRK-13] SHORT-CIRCUITED LIFT ARM RAISE MAGNET DETENT OUTPUT SYSTEM 876
TROUBLESHOOTING CODE [WRK-14] SHORT-CIRCUITED LIFT ARM FLOATING MAGNET DETENT OUTPUT SYSTEM 877
TROUBLESHOOTING CODE [WRK-15] SHORT-CIRCUITED BUCKET TILT MAGNET DETENT OUTPUT SYSTEM 878
TROUBLESHOOTING CODE [WRK-16] SHORT-CIRCUITED WORK EQUIPMENT NEUTRAL LOCK SOLENOID OUTPUT SYSTEM 879
TROUBLESHOOTING CODE [WRK-17] SHORT-CIRCUITED LIFT ARM RAISE EPC SOLENOID SYSTEM 880
TROUBLESHOOTING CODE [WRK-18] SHORT-CIRCUITED LIFT ARM LOWER EPC SOLENOID SYSTEM 881
TROUBLESHOOTING CODE [WRK-19] SHORT-CIRCUITED BUCKET TILT EPC SOLENOID SYSTEM 882
TROUBLESHOOTING CODE [WRK-20] SHORT-CIRCUITED BUCKET DUMP EPC SOLENOID SYSTEM 883
TROUBLESHOOTING CODE [WRK-21] SHORT-CIRCUITED 3 VALVES EXTENSION EPC SOLENOID SYSTEM 884
TROUBLESHOOTING CODE [WRK-22] SHORT-CIRCUITED 3 VALVES RETRACTION EPC SOLENOID SYSTEM 885
TROUBLESHOOTING CODE [WRK-23] SHORT-CIRCUITED JOYSTICK STEERING RIGHT EPC SOLENOID SYSTEM 886
TROUBLESHOOTING CODE [WRK-24] SHORT-CIRCUITED JOYSTICK STEERING LEFT EPC SOLENOID SYSTEM 887
TROUBLESHOOTING CODE [WRK-25] DEFECTIVE BUCKET POSITIONER,LIFT ARM KICK-OUT AND FLOATING MAINTENANCE FUNCTION 888
TROUBLESHOOTING CODE [WRK-26] DEFECTIVE LIFT ARM KICK-OUT FUNCTION AND CANCELLATION 890
TROUBLESHOOTING CODE [WRK-27] DEFECTIVE BUCKET LEVELER FUNCTION AND CANCELLATION 892
TROUBLESHOOTING CODE [WRK-28] DEFECTIVE LIFT ARM FLOATING MAINTENANCE AND CANCELLATION 894
TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE) 897
MONITOR SYSTEM DIAGRAM 900
FAILURE CODE [2F00MA] DEFECTIVE PARKING BRAKE SYSTEM 904
FAILURE CODE [2G42ZG] ACCUMULATOR OIL PRESSURE (FRONT CIRCUIT) LOW 906
FAILURE [2G43ZG] ACCUMULATOR OIL PRESSURE (REAR BRAKE CIRCUIT) LOW 907
FAILURE CODE [AA1ANX] AIR CLEANER 1 CLOGGED 908
FAILURE CODE [AB00L6] DEFECTIVE BATTERY CHARGING CIRCUIT (ALTERNATOR TERMINAL R SIGNAL DETECTED WHEN ENGINE STOPPED 910
FAILURE CODE [AB00MA] DEFECTIVE BATTERY CHARGING CIRCUIT (NO ALTERNATOR TERMINAL R SIGNAL DETECTED,DETECTION FAILURE) 911
FAILURE CODE [B@BAZG] ENGINE OIL PRESSURE LOW 912
FAILURE CODE [B@BAZK] ENGINE OIL LEVEL LOW 913
FAILURE CODE [B@BCNS] ENGINE WATER TEMPERATURE OVERHEATING 914
FAILURE CODE [B@BCZK] ALARM INDICATING LOW COOLANT LEVEL 915
FAILURE CODE [B@HANS] HYDRAULIC OIL TEMPERATURE OVERHEATING 916
FAILURE CODE [B@CENS] TORQUE CONVERTER OIL TEMPERATURE OVERHEATING 917
FAILURE CODE [D5ZHL6] STARTING SWITCH C (IGN”C”) INPUT FAILURE 918
FAILURE CODE [DA80L4] AUTO GREASE INPUT FAILURE 919
FAILURE CODE [DAF3KK] SW POWER SUPPLY (FOR OPERATION) = ON AND NSW POWER SUPPLY (FOR MEMORY) = OFF 920
FAILURE CODE [DAF5KP] 5-V POWER SUPPLY OUTPUT FAILURE 922
FAILURE CODE [DAF6KP] 24-V POWER SUPPLY OUTPUT FAILURE 924
FAILURE CODE [DAFBKM] WRONG INFORMATION ON MODEL SELECTION 926
FAILURE CODE [DAFSKQ] WRONG INFORMATION ON METER DISPLAY SELECTION 927
FAILURE CODE [DAQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND TRANSMISSION CONTROLLER) SELECTION 928
FAILURE CODE [DBQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) 929
FAILURE CODE [DB9SKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) 930
FAILURE CODE [DD15LD] MONITOR PANEL MODE SELECTOR SWITCH 1 [■](PANEL SW1) INPUT ERROR 931
FAILURE CODE [DD16LD] MONITOR PANEL MODE SELECTOR SWITCH 1 [◇](PANEL SW2) INPUT ERROR 932
FAILURE CODE [DD17LD] MONITOR PANEL MODE SELECTOR SWITCH 2 [＜](PANEL SW3) INPUT ERROR 933
FAILURE CODE [DD18LD] MONITOR PANEL MODE SELECTOR SWITCH 2 [＞](PANEL SW4) INPUT ERROR 934
FAILURE CODE [DD1CLD] SUB-TOTAL SWITCH FAILURE (*) 936
FAILURE CODE [DDS5L6] DECREASED STEERING OIL PRESSURE 938
FAILURE CODE [DDY0LD] CANCEL SWITCH FAILURE (*) 940
FAILURE CODE [DGE2KX] ENGINE WATER TEMPERATURE SENSOR SYSTEM FAILURE 941
FAILURE CODE [DGH2KX] HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM FAILURE 942
FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM FAILURE 943
FAILURE CODE [DHE4L6] ENGINE OIL PRESSURE SENSOR SYSTEM FAILURE 944
FAILURE CODE [DHPCKX] BOTTOM PRESSURE SENSOR FAILURE (*) 946
FAILURE CODE [DHPDKX] HEAD PRESSURE SENSOR FAILURE (*) 948
FAILURE CODE [DKA0KX] BOOM ANGLE SENSOR FAILURE (*) 949
FAILURE CODE [DV00KB] SHORT-CIRCUITED ALARM BUZZER OUTPUT SYSTEM 950
FAILURE CODE [DY30ME] THE EMERGENCY STEERING REMAINS ACTUATED FOR MORE THAN ONE MINUTE 952
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) 954
TROUBLESHOOTING CODE [MON-2] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (FRONT CIRCUIT) 956
TROUBLESHOOTING CODE [MON-3] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (REAR CIRCUIT) 957
TROUBLESHOOTING CODE [MON-4] THE AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT ON 958
TROUBLESHOOTING CODE [MON-5] THE ENGINE HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON 960
TROUBLESHOOTING CODE [MON-6] THE ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT ON 961
TROUBLESHOOTING CODE [MON-7] THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON 962
TROUBLESHOOTING CODE [MON-8] THE RADIATOR WATER VOLUME CAUTION LAMP DOES NOT LIGHT ON 963
TROUBLESHOOTING CODE [MON-9] THE HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON AFTER THE ENGINE STARTS, THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT RISE 964
TROUBLESHOOTING CODE [MON-10] THE TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON AFTER THE ENGINE STARTS, THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT RISE 965
TROUBLESHOOTING CODE [MON-11] THE STEERING HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON 966
TROUBLESHOOTING CODE [MON-12] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 [■] (PANEL SW1) 967
TROUBLESHOOTING CODE [MON-13] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 [◇] (PANEL SW2) 968
TROUBLESHOOTING CODE [MON-14] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 [<] (PANEL SW3) 969
TROUBLESHOOTING CODE [MON-15] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 [>] (PANEL SW4) 970
TROUBLESHOOTING CODE [MON-16] DEFECTIVE SUBTOTAL SWITCH 971
TROUBLESHOOTING CODE [MON-17] DEFECTIVE CANCEL SWITCH 972
TROUBLESHOOTING CODE [MON-18] DEFECTIVE BOTTOM PRESSURE SENSOR (HOT SHORT FAULT) 973
TROUBLESHOOTING CODE [MON-19] DEFECTIVE HEAD SENSOR 974
TROUBLESHOOTING CODE [MON-20] THE ALARM BUZZER DOES NOT SOUND OR STOP (DISCONNECTION IN ALARM BUZZER OUTPUT SYSTEM, OR GROUND FAULT) 975
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 977
H-1 THE MACHINE DOES NOT START 978
H-2 THE LOCK UP CLUTCH IS NOT RELEASED (THE ENGINE STOPS)(WHEN THE LOCK-UP CLUTCH IS PROVIDED) 980
H-3a THE TRAVEl SPEED IS SLOW,THE THRUSTING FORCE IS WEAK,THE UPHILL TRAVELING POWER IS WEAK,AND THE GEAR IS NOT SHIFTED 981
H-3b THE TORQUE CONVERTER LOCK-UP CLUTCH IS NOT LOT IN(WHEN THE LOCK-UP CLUTCH IS PROVIDED 983
H-4 SHOCKS ARE LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR 984
H-5 TIME LAG IS LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR 986
H-6 THE TORQUE CONVERTER OIL TEMPERATURE IS HIGH 988
H-7 THE STEERING WHEEL DOES NOT TURN 989
H-8 THE STEERING WHEEL IS HEAVY 990
H-9 THE STEERING WHEEL FLUCTUATES OR IS STRONGLY SHOCKED 991
H-10 THE MACHINE STEERS TO ONE SIDE WHEN TRAVELING 991
H-11 THE RIGHT AND LEFT SWING RADII ARE DIFFERENT 991
H-12 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL 992
H-13 THE BRAKE IS NOT RELEASED OR IS DRAGGED 993
H-14 THE BRAKE IS NOT RELEASED OR DRAGGED 994
H-15 THE LIFT ARM DOES NOT RISE 995
H-16 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT 996
H-17 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT 997
H-18 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR) 997
H-19 HYDRAULIC DRIFTS OF THE LIFE ARM OCCUR OFTEN 997
H-20 THE LIFT ARM WOBBLES DURING OPERATION 997
H-21 WHEN THE CONTROL LOVER IS SWITCHED FROM “HOLD” TO “RAISE,” THE LIFT ARM FALLS TEMPORARILY 998
H-22 THE BUCKET DOES NOT TILT BACK 999
H-23 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT 1000
H-24 THE BUCKET COMES TO OPERATE SLOWLY IN THE MIDST OF TILTING-BACK 1001
H-25 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET 1001
H-26 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN 1001
H-27 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO “HOLD”) 1002
H-28 WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “TILT,” THE BUCKET FALLS TEMPORARILY 1002
H-29 THE CONTROL LOVERS OF LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY 1003
H-30 ECSS DOES NOT WORK,AND THERE IS PITCHING AND BOUNCING 1004
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 1005
ELECTRICAL SYSTEM DIAGRAM 1006
TROUBLESHOOTING CODE [E-1-a] (THE FRONT WIPER DOES NOT FUNCTION) 1007
TROUBLESHOOTING CODE [E-1-b] (THE REAR WIPER DOES NOT FUNCTION) 1010
TROUBLESHOOTING CODE [E-1-c] (THE SIDE WIPER DOES NOT FUNCTION)(IF EQUIPPED) 1011
TROUBLESHOOTING CODE [E-2] (THE WIND WASHER DOES NOT FUNCTION) 1012
TROUBLESHOOTING CODE [E-3-a] (THE HEADLAMP (LO BEAM) DOES NOT LIGHT ON) 1015
TROUBLESHOOTING CODE [E-3-b] (THE HEADLAMP (HI BEAM) DOES NOT FUNCTION) 1018
TROUBLESHOOTING CODE [E-3-c] (THE CLEARANCE LAMP DOES NOT LIGHT ON (SMALL LAMP) 1020
TROUBLESHOOTING CODE [E-3-d] (THE TURN SIGNAL DOES NOT BLINK) 1021
TROUBLESHOOTING CODE [E-4] (THE HORN DOES NOT SOUND) 1023
TROUBLESHOOTING CODE [E-5] (THE AIR CONDITIONER DOES NOT WORK OR DOES NOT STOP) 1025
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 1029
POINTS TO REMEMBER WHEN TROUBLESHOOTING 1030
METHOD OF USING TROUBLESHOOTING CHARTS 1031
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 1035
S-2 ENGINE DOES NOT START 1036
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 1039
S-4 ENGINE STOPS DURING OPERATIONS 1040
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 1041
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 1042
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 1043
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 1044
S-9 OIL BECOMES CONTAMINATED QUICKLY 1045
S-10 FUEL CONSUMPTION IS EXCESSIVE 1046
S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN) 1047
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 1048
S-13 OIL LEVEL RISES (COOLANT, FUEL IN OIL) 1049
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 1050
S-15 ABNORMAL NOISE IS MADE 1051
S-16 VIBRATION IS EXCESSIVE 1052
30 DISASSEMBLY AND ASSEMBLY 1053
HOW TO READ THIS MANUAL 1056
PRECAUTIONS WHEN PERFORMING OPERATION 1059
SPECIAL TOOL LIST 1062
SKETCHES OF SPECIAL TOOLS 1067
FUEL SUPPLY PUMP ASSEMBLY 1080
SPECIAL TOOLS 1080
REMOVAL 1080
INSTALLATION 1082
FUEL INJECTOR ASSEMBLY 1085
REMOVAL 1085
INSTALLATION 1087
NOZZLE TIP 1089
SPECIAL TOOL 1089
REMOVAL 1089
INSTALLATION 1090
CYLINDER HEAD ASSEMBLY 1092
SPECIAL TOOL 1092
REMOVAL 1092
INSTALLATION 1096
RADIATOR ASSEMBLY 1099
REMOVAL 1099
INSTALLATION 1100
AIR AFTERCOOLER ASSEMBLY 1101
REMOVAL 1101
INSTALLATION 1101
COOLONG FAN DRIVE MOTOR 1102
REMOVAL 1102
INSTALLATION 1102
ENGINE ASSEMBLY 1103
REMOVAL 1103
INSTALLATION 1107
STEERING, SWITCH PUMP, COOLING FAN DRIVE PUMP ASSEMBLY 1108
REMOVAL 1108
INSTALLATION 1109
TORQUE CONVERTER CHARGE, WORK EQUIPMENT AND PPC PUMP ASSEMBLY 1110
REMOVAL 1110
INSTALLATION 1110
TORQUE CONVERTER, TRANSMISSION ASSEMBLY 1111
REMOVAL 1111
INSTALLATION 1114
TORQUE CONVERTER ASSEMBLY (STANDARD SPECIFICATIONS) 1116
SPECIAL TOOLS 1116
DISASSEMBLY 1116
ASSEMBLY 1117
TORQUE CONVERTER ASSEMBLY (LOCK-UP SPECIFICATIONS) 1120
SPECIAL TOOLS 1120
DISASSEMBLY 1120
ASSEMBLY 1122
TRANSMISSION ASSEMBLY 1127
SPECIAL TOOLS 1127
DISASSEMBLY 1127
ASSEMBLY 1133
TRANSMISSION CLUTCH PACK ASSEMBLY 1143
SPECIAL TOOLS 1143
DISASSEMBLY 1143
ASSEMBLY 1149
PARKING BRAKE ASSEMBLY 1162
SPECIAL TOOLS 1162
DISASSEMBLY 1162
ASSEMBLY 1164
FRONT AXLE ASSEMBLY 1170
DISASSEMBLY 1170
ASSEMBLY 1171
REAR AXLE ASSEMBLY 1172
REMOVAL 1172
INTALLATION 1174
AXLE HOUSING ASSEMBLY 1176
SPECIAL TOOLS 1176
DISASSEMBLY 1176
ASSEMBLY 1179
DIFFERENTIAL ASSEMBLY 1186
SPECIAL TOOLS 1186
DISASSEMBLY 1186
ASSEMBLY 1193
CENTER HINGE PIN 1208
SPECIAL TOOLS 1208
REMOVAL 1208
INSTALLATION 1212
STEERING VALVE ASSEMBLY 1216
REMOVAL 1216
INSTALLATION 1217
STEERING VALVE OIL SEAL 1218
REMOVAL 1218
INSTALLATION 1219
ECSS ASSEMBLY 1220
REMOVAL 1220
INSTALLATION 1220
PARKING BRAKE DISC 1221
SPECIAL TOOLS 1221
REMOVAL 1221
INSTALLATION 1223
HYDRAULIC TANK 1224
REMOVAL 1224
INSTALLATION 1225
WORK EQUIPMENT VALVE ASSEMBLY 1226
REMOVAL 1226
INSTALLATION 1227
HYDRAULIC CYLINDER ASSEMBLY 1228
SPECIAL TOOLS 1228
DISASSEMBLY 1228
ASSWMBLY 1231
WORK EQUIPMENT ASSEMBLY 1236
REMOVAL 1236
INSTALLATION 1238
COUNTERWEIGHT 1241
REMOVAL 1241
INSTALLATION 1241
FUEL TANK ASSEMBLY 1242
REMOVAL 1242
INSTALLATION 1242
CAB ASSEMBLY 1243
REMOVAL 1243
INSTALLATION 1245
CAB, FLOOR FRAME ASSEMBLY 1246
REMOVAL 1246
INSTALLATION 1249
OPERATOR’S CAB GLASS (STUCK GLASS) 1250
SPECIAL TOOLS 1250
REMOVAL 1250
INSTALLATION 1251
AIR CONDITIONER UNIT ASSEMBLY 1258
REMOVAL 1258
INSTALLATION 1260
AIR CONDITIONER COMPRESSOR ASSEMBLY 1261
SPECIAL TOOLS 1261
REMOVAL 1261
INSTALLATION 1261
OPERATOR’S SEAT ASSEMBLY 1262
DISASSEMBLY 1262
ASSEMBLY 1267
90 OTHERS 1271
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 1273
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (FOR ELECTRIC WORK EQUIPMENT LEVER) 1275
POWER TRAIN OIL CIRCUIT DIAGRAM (WITHOUT TORQUE CONVERTER LOCKUP CLUTCH) 1277
POWER TRAIN OIL CIRCUIT DIAGRAM (WITH TORQUE CONVERTER LOCKUP CLUTCH) 1279
BRAKE OIL CIRCUIT DIAGRAM 1281
ELECTRICAL CIRCUIT DIAGRAM(1/8)(1/4) 1283
ELECTRICAL CIRCUIT DIAGRAM(1/8)(2/4) 1285
ELECTRICAL CIRCUIT DIAGRAM(1/8)(3/4) 1287
ELECTRICAL CIRCUIT DIAGRAM(1/8)(4/4) 1289
ELECTRICAL CIRCUIT DIAGRAM(2/8)(1/4) 1291
ELECTRICAL CIRCUIT DIAGRAM(2/8)(2/4) 1293
ELECTRICAL CIRCUIT DIAGRAM(2/8)(3/4) 1295
ELECTRICAL CIRCUIT DIAGRAM(2/8)(4/4) 1297
ELECTRICAL CIRCUIT DIAGRAM(3/8) 1299
ELECTRICAL CIRCUIT DIAGRAM(4/8) 1301
ELECTRICAL CIRCUIT DIAGRAM(5/8) 1303
ELECTRICAL CIRCUIT DIAGRAM(6/8) 1305
ELECTRICAL CIRCUIT DIAGRAM(7/8) 1307
ELECTRICAL CIRCUIT DIAGRAM(8/8) 1309
AXLE OIL TEMPERATURE GAUGE ELECTRICAL CIRCUIT DIAGRAM 1311

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