Service manual Komatsu WA380-6 A54001 & Up | CEBM022701

Komatsu WA380-6 A54001 & Up CEBM022701 (Preview)

COVER
– CONTENTS
– LIST OF REVISED PAGES
– SAFETY
— Safety Notice
— General Precautions
— Preparations for Work
— Precautions During Work
– GENERAL
– HOW TO READ THE SHOP MANUAL
— Volumes
— Distribution and Updating
— Filing Method
— Revised Edition Mark
— Revisions
— Symbols
– HOISTING INSTRUCTIONS
— Hoisting
— Making Signs
— Precautions
— Precautions for Sling Work
— Precautions for Using Mobile Crane
— Precautions for Using Overhead Hoist Crane
— Selecting Wire Ropes
– AIR CONDITIONER CIRCUITS
— Precautions for Handling Hoses and Tubes
— Disconnecting Hoses and Tubes
— Connecting Hoses and Tubes
– MAINTENANCE STANDARD TERMS
– HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT
— Handling Electric Equipment
— Handling Wiring Harnesses and Connectors
— Main Failures Occurring in Wiring Harness
— Removing, Installing, and Drying Connectors and Wiring Harnesses
— Handling Controller
— Troubleshooting Electric Circuits
— Handling Hydraulic Equipment
— Handling Connectors Used for Engines
— Slide Lock Type
— Pull Lock Type
— Push Lock Type
— Turn-housing Type (Round Green Connector)
– PRECAUTIONS FOR OPERATIONS
— Precautions when Carrying Out Removal Work
— Precautions when Carrying Out Installation Work
— Precautions when Completing the Operation
– PUSH-PULL COUPLER
— Type 1
— Disconnection
— Connection
— Type 2
— Disconnection
— Connection
— Type 3
— Disconnection
— Connection
– COATING MATERIALS
– STANDARD TIGHTENING TORQUE
— Standard Tightening Tables
— For Bolts and Nuts
— For Split Flange Bolts
— For O-Ring Boss Piping Joints
— For O-Ring Boss Plugs
— For Hoses (Taper-Seal Type and Face-Seal Type)
— For Face Seal Joints
— For 102, 107, and 114 Engine Series (Bolts and Nuts)
— For 102, 107, and 114 Engine Series (Eye Joints)
— For 102, 107, and 114 Engine Series (Taper Screws)
– CONVERSION TABLES
— Method of Using the Conversion Table
01 GENERAL
– SPECIFICATIONS
— Dimension Drawing
— Specification Tables
– WEIGHT TABLE
– FUEL, COOLANT, AND LUBRICANTS
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
– ENGINE AND COOLING SYSTEM
— Engine and Transmission Mounting
— Torque Values
— Cooling System
— Specifications
— Cooling Fan Pump
— Type: LPV30
— Torque Values
— Torque Values
— Function
— Structure
— Operation
— Control of Delivery
— Servo Valve
— Torque Values
— Function
— Cooling Fan Motor System
— Type: LMF28
— Specifications
— Torque Values
— Hydraulic Motor
— Function
— Principle of Operation
— Suction Valve
— Function
— Operation
— Reversible Valve
— Safety Valve
— Function
— Operation
– POWER TRAIN SYSTEM
— Drive Line Components
— Outline
— System Diagram
— Outline
— Drive Shaft System
— Torque Values
— Outline
— Power Train Piping System
— Torque Converter
— Without Lockup Clutch
—- Specifications
—- Torque Values
— Power Transmitting Route
— Oil Flow
— With Lockup Clutch
—- Specification
—- Torque Values
— Torque Flow
— When Lockup Clutch Is Disengaged
— When Lockup Clutch Is Engaged
— Oil Flow
— Transmission
— With Lockup Clutch
—- Torque Values
—- Outline
—- Torque Values
—- Torque Values
— Forward and Reverse Clutches
— Without Lockup Clutch
— With Lockup Clutch
— 1st and 4th Clutches
— 2nd and 3rd Clutches
— Operation of Clutch Pack
—- When clutch is engaged
—- When clutch is disengaged
— Transmission Torque Flow Route
— Forward 1st Gear Speed
— Forward 2nd Gear Speed
— Forward 3rd Gear Speed
— Forward 4th Gear Speed
— Reverse 1st Gear Speed
— Flow Control Valve
— Torque Values
— Operation
— Valve Assembly
—- Torque Values
— ECMV System
— For R, 1st, and 2nd Clutches
—- Torque Values
— For F, 3rd, 4th, and Lockup Clutches
— ECMV For Gear Speed Clutch
—- Outline of ECMV
—- ECMV and Proportional Solenoid
—- ECMV and Fill Switch
—- Operation of ECMV
—- Before Shifting Gear (when draining) (Range A in chart)
—- During filling (Range B in chart)
—- Pressure regulation (Range C in chart)
— ECMV for Lockup Clutch
—- Outline
—- Operation
—- When Traveling in Direct Range
—- During Filling
—- Pressure Adjustment
— Main and Torque Converter Relief Valve System
— Torque Values
— Outline
—- Torque Converter Relief Valve
—- Main Relief Valve
— Operation
—- Torque Converter Relief Valve
—- Operation of Main Relief Valve
– DRIVE AXLE SYSTEM
— Front Axle Assembly
— Rear Axle Assembly
— Front Differential
— Torque Values
— Rear Differential
— Torque Values
— Outline
— While Machine is Traveling Straight
— When Machine Is Turning
— Limited Slip Differential
— Front Axle Carrier
— Torque Values
— Rear Axle Carrier
— Torque Values
— Operation of Limited Slip Differential
— Generation of Braking Torque by Right / Left Side Gears (5)
— While Machine is Traveling Straight
— When Machine Is Turning
— Final Drive
— Outline
— Torque Values
– STEERING SYSTEM
— Steering Piping Diagram
— Steering Column
— Torque Values
— Steering Pump
— Type: LPV63
— Torque Values
— Pump Unit
—- Torque Values
—- Function
—- Structure
—- Operation of Pump
—- Control of Discharge Amount
— Servo Valve
—- Torque Values
— LS Valve
—- Function
— PC Valve
—- Function
—- Operation of Spring
—- When pump pressure (PA) is low
—- When pump pressure (PA) is high
— Steering Valve
— Operation of Flow Amplifier
—- When Spool is at Neutral (when Orbitrol valve is not in operation)
—- When Spool is in Operation (when oil flows in port (Pa))
—- When Spool is Returned (when steering wheel is stopped)
— Operation of Flow Control Spool
—- When Steering Spool is at Neutral Position
—- When Steering Spool Operates
— Operation of Steering Valve
—- At Neutral
—- Turning Left
—- Turning Right
— Steering Relief Valve
—- Function
—- Operation
— Overload Relief Valve
—- Function
—- Operation as Relief Valve
—- Operation as Suction Valve
— Relief Valve
—- Function
— Orbitrol Valve
— Torque Values
— Outline
— Structure
— Connection of Hand Pump and Sleeve
— Role of Centering Spring
— Stop Valve
— Steering Relief Valve
— Torque Values
— Outline
— Steering Cylinder
— Emergency Steering Motor
— Function
— Specifications
— Emergency Steering Pump (If Equipped)
— Type: SBL (1) 21
— Torque Value
— Function
— Joystick Steering Lever Linkage
— Steering Electric Lever
— Function
— Joystick EPC Valve
— Torque Values
— Function
— Multi-Function Lever & Joystick Lever (Modification)
— Required
— Procedure
– SERVICE BRAKING SYSTEM
— Brake Piping Diagram
— Charge Valve
— Torque Value
— Torque Values
— Function
— Operation
— When Oil is Not Supplied to Accumulator (cut-out state)
— When Oil is Supplied to Accumulator (cut-in state)
— When Cut-out Pressure is Reached
— Main Relief Valve (R1)
— PPC Relief Valve (R3)
— Sequence Valve (H1)
— Shuttle Valve (S1)
— Brake Valve
— Outline
— Operation
— When the Brake Pedal is Depressed
— When Brake on One Side is Operated
— Balancing Operation
— When Brake Pedal is Released
— Accumulator (for Brakes)
— Function
— Specifications
— Front Brake
— Outline
— Rear Brake
— Outline
— Operation
— When Brake is Operated
— When Brake is Released
– PARKING BRAKE SYSTEM
— Brake Control
— Outline
— Parking Brake Unit
— Outline
— Torque Values
— Parking Brake Solenoid Valve
— Torque Values
— Operation
— When Parking Brake is Applied (When solenoid is de-energized)
— When Parking Brake is Released (When solenoid is energized)
— Emergency Parking Brake Release Valve
— Function
– UNDERCARRIAGE AND FRAME
— Axle Mounting and Center Hinge Pin
— Torque Values
— Outline
— Torque Values
— Tires
— Radial Ply Tire
— Bias Tire
– HYDRAULIC SYSTEM
— Piping Diagram
— Outline
— Work Equipment Control Lever System
— Multi-Function Mono-Lever Type
— Hydraulic Tank
— Specifications
— Tank Vent System
— Power Train Pump
— Type: SDL (30)80
— Outline
— Work Equipment Pump
— Type: LPV90
— Torque Values
— Pump Unit
— Servo Valve
—- Torque Values
—- Function
—- Structure
—- Operation of Pump
—- Control of Delivery
— LS Valve
—- Function
— PC valve
—- Function
—- Operation
—- When Load is Light (Fig.1)
—- When Load is Heavy (Fig.2)
—- When Balanced (Fig.3)
— Work Equipment Control Valve
— Outline
— 4-Spool Valve
—- General View
—- Torque Values
—- Sectional View of Valve (1/7)
—- Torque Values
—- Sectional View of Valve (2 /7)
—- Sectional View of Valve (3/7)
—- Sectional View of Valve (4/7)
—- Sectional View of Valve (5/7)
—- Sectional View of Valve (6/7)
—- Sectional View of Valve (7/7)
— CLSS
— Outline of CLSS
—- Features
—- Structure
— Basic Principle
—- Pump Swash Plate Angle Control
— Pressure Compensation Control
— Function and Operation of Each Valve
— Hydraulic Circuit Diagram of Valves
— Unload Valve
—- When Control Valve is at Neutral Position
—- When Control Valve is Controlled Finely
—- When Control Valve is Operated
— Work Equipment Valve (Supply of LS Pressure)
—- Work Equipment Valve (Lift Arm)
—- Work Equipment Valve (Bucket and Service)
— LS Bypass Plug
— Pressure Compensation Valve
— Lift Arm Regeneration Circuit
—- When Lift Arm is Lowered
—- Function
—- Operation
— Variable Lift Check Valve
—- Function
—- Operation
— ECSS Control Valve
— Function
— Operation
— Restriction on Lift Arm Raise Stroke
— Function
— Operation
— Accumulator Charge Valve
— Pressure
— When Valve is in Neutral and (P) is Low
— Function
— Operation
— When Load Pressure (P) is High
— Operation
— PPC Valve
— Work Equipment PPC Valve
— Operation
— When In Neutral
— During Fine Control
— Stabilizer Valve
— Function
— When in Neutral
— Operation
— Main Spool (9) is Moved from Neutral to Operating Position
— Operation
— Main Spool (9) is Moved from Operating Position to Neutral
— Operation
— Main Spool (9) is Moved From Operating Position to Neutral (at Low Temperature)
— Operation
— Work Equipment PPC Cutoff Solenoid Valve
— Outline
— Operation
— Accumulator (for PPC Circuit)
— Outline
— Specifications
— Accumulator (for ECSS)
— Function
— Specifications
– WORK EQUIPMENT
— Work Equipment Linkage
— Bucket
— Bucket Positioner and Boom Kickout
— Bucket Positioner
— Boom Kick-out
— Proximity Switch
—- When Bucket Is Tilted
—- Function of Proximity Switch
—- When Lift Arm Is Raised
—- Function of Proximity Switch
— Work Equipment Cylinders
— Lift Cylinder
— Bucket Cylinder
– CAB ENVIRONMENT
— ROPS Cab
— Air Conditioner
— Air Conditioner Piping Diagram
—- Specifications
— Refrigerant Circuit Diagram
— Air Conditioner Unit
—- (Automatic Air Conditioner)
—- Outline
—- Cooler
—- Heater
—- Functions of Major Components
—- Evaporator
—- Heater Core
—- Expansion Valve
—- Blower Controller
—- Blower Motor Relay
—- Compressor Clutch Relay
—- Air Mix Damper Actuator
—- Mode Selector Damper Actuator
—- Evaporator Temperature Sensor
—- Dual Pressure Switch
—- Sunlight Sensor
— Blower and Intake Unit
—- Automatic Air Conditioner
—- Functions of Major Components
— Refrigerant Compressor
—- Function
—- Specifications
— Condenser
—- Function
—- Specifications
— Receiver
—- Function
—- Specifications
— Air Conditioner Panel
—- Display Unit
—- Switch Block
—- Outline
– ELECTRICAL SYSTEM
— Machine Monitor System
— Outline
— Operator Mode
— Service Mode
— System Circuit Diagram
— Machine Monitor
—- Speedometer Specification
— Items Displayed on Monitor
— Machine Monitor Operation Switches
— Setting Machine Monitor
— Troubleshooting Function
— Character Display Function
— Operator Mode Functions
—- Self-Check Screen (0th layer)
—- Normal Screen (1st layer)
—- Failure Code Screen (1st layer)
—- Display of Functions Available for the Operator (2nd layer or below)
— Service Mode Functions
—- Procedure for Switching to Service Mode
—- Service Mode Menu
—- Electrical System Failure History Display Function (ELECTRIC FAULT)
—- Mechanical System Failure History Display Function (MACHINE FAULT)
—- Real-Time Monitoring Function (REAL-TIME MONITOR)
—- Engine Reduced-Cylinder Function (CYLINDER CUT-OUT)
—- No Injection Cranking Function (NO INJECTION)
—- Adjustment Function (TUNING)
—- Maintenance Monitoring Function (MAINTENANCE MONITOR)
—- Operating Information Display Function (OPERATION INFO)
—- Optional Device Selecting Function (OPTIONAL SELECT)
—- Machine Serial Number Input Function (MACHINE No. SET)
—- Model Selection Function (MACHINE)
—- Initialize Function (INITIALIZE)
— Input and Output Signals
— Transmission Controller System
— Gearshifting Control Function
—- Electronic Modulation Function
—- Gearshifting Display Function
—- Automatic Gearshifting Function
—- Auto-Shift Points Table
—- Auto-Shift Points
—- Shift Hold Function
—- Kickdown Function
—- Torque Converter Lockup Function
—- Lockup Operating Points Table
—– Forward
—– Reverse
—- Hunting Protection Function
—- Changing Shift Points
—- 4th Gear Speed Derating Function
—- Transmission Controller Protection Function
—- Shift-Down Protection Function
—- Engine Overrun Prevention Function
—- Maximum Travel Speed Derating Function
—- Neutralizer Function
—- Engine Control Function
—- Economy Operation Pilot Lamp Function
— Cooling Fan Control Function
—- Fan Control
—- Pump Protection Function
—- Control at Start of Engine
—- Fan Reverse Rotation Function
— Work Equipment Pump Swash Plate Control Function
—- Engine Stop Prevention Control at Low Idle
—- Pickup Auxiliary Function when Engine Speed is Low
— Transmission Cutoff Function
— ECSS Function
—- Outline
—- Setting Method
—- Operation
— Electric Emergency Steering Function
—- Outline
—- Setting method
—- Self-Check Operation of Emergency Steering
— Directional Selector Switch Control Function
—- Operation of Directional Selector Switch
—- Safety Function at Start of Engine
—- Setting Method
— Multi-Function Mono Lever Function
—- Operation of FNR Switch
—- Safety Function at Start of Engine
—- Shift Hold Function
—- Kickdown Function
—- Setting Method
— Joystick Steerin Function
—- Operation of Directional Selector Switch
—- Safety Function at Start of Engine
—- Shift-Up and Shift-Down Function
—- Setting Method
— System Circuit Diagram
— Transmission Controller
—- Input and Output Signals
— Work Equipment Controller System
— Safety Function for Starting Engine
— Safety Function for Selecting Joystick Steering System
— Steering Speed Selecting Function
— Travel Speed-Sensitive Steering Function
— Adjusting Starting Current
— Setting Method
— Troubleshooting Function
— System Circuit Diagram
— Work Equipment Controller
—- Input and Output Signals
– ELECTRONIC TRANSMISSION CONTROL
— Function
— Combination Switch
— Outline
— Function
— Operation
– KICKDOWN AND HOLD SWITCH
— Load Meter Cancel Switch and Load Meter Subtotal Switch
— Function
– MULTI-FUNCTION KNOB
— Function
— Modification of Multi-Function Lever
— Required
— Procedure
– JOYSTICK STEERING KNOB
— Function
– KOMTRAX TERMINAL SYSTEM
— KOMTRAX Terminal
— Model TC301
— Outline
— Input and Output Signals
– ENGINE STARTING CIRCUIT
— Function
— Operation
– ENGINE STOPPING CIRCUIT
— Operation
– PREHEATING CIRCUIT
— Outline
— Operation
– ENGINE POWER MODE SELECTOR CIRCUIT
— Function
— Operation
– ENGINE OUTPUT DERATING FUNCTION
– AUTOMATIC WARM-UP FUNCTION
– PARKING BRAKE CIRCUIT
— Operation
— When ignition switch is turned OFF
— When ignition switch is turned ON
— When low oil pressure occurs on main brake (when emergency brake is applied)
– SENSORS
— Speed Sensor
— Torque Converter Oil Temperature Sensor
— Hydraulic Oil Temperature Sensor
— Transmission Oil Temperature Sensor
— Brake Oil Temperature Sensor
— Work Equipment Pump Oil Pressure Sensor
— Steering Pump Oil Pressure Sensor
— Lift Cylinder Head Oil Pressure Sensor
— Lift Cylinder Bottom Oil Pressure Sensor
— Transmission Cutoff Oil Pressure Sensor
— Coolant Lever Sensor
— Fuel Level Sensor
— Air Cleaner Clogging Sensor
— Accelerator Pedal Sensor
— Torque Values
— Function
— Accelerator signal
— Idle Validation Signal
— Water-In-Fuel Sensor
— Boom Kickout Proximity Switch
— Bucket Positioner Proximity Switch
— Lift Arm Potentiometer
20 STANDARD VALUE TABLES
– STANDARD VALUE TABLES
— Service Value For Engine
— Service Values For Chassis
– POSTURE AND PERFORMANCE MEASUREMENTS
— Machine Posture
30 TESTING AND ADJUSTING
– TOOLS
— Tools for Testing, Adjusting, and Troubleshooting
– ENGINE COMPONENTS
— Engine Speed
— Measurement Conditions
— Measure Engine Speed (Low and High Idle)
— Measure Torque Converter Stall Speed
— Measure Hydraulic Stall Speed
— Measure Torque Converter Stall and Hydraulic Stall (Full Stall) Speed
— Exhaust Gas Color
— Special Tools Required
— Measurement Condition
— Using Handy Smoke Checker A1
— Using Smoke Meter A2
— Valve Clearance
— Special Tools Required
— Measurement Condition
— Engine Compression
— Special Tools Required
— Measurement Condition
— Blow-by Pressure
— Special Tools Required
— Measurement Conditions
— Engine Oil Pressure
— Special Tools Required
— Measurement Condition
— Intake Air (Boost) Pressure
— Special Tool Required
— Measurement Condition
— Determining a Defective Cylinder
— Procedures
— Determining Cylinder Group
— Isolating the Defective Cylinder
– FUEL SYSTEM
— Handling Fuel System Equipment
— Precautions for Testing and Maintaining Fuel System
— Precautions for Replacement of Fuel Filter Cartridge
— Releasing Residual Pressure in Fuel System
— Measuring Fuel Pressure
— Special Tools Required
— Measuring Pressure in Fuel Low-pressure Circuit
— Measuring Pressure in Fuel Return Circuit
— Measuring Fuel Negative-Pressure Circuit Pressure
— Fuel Delivery, Return, and Leak Rate
— Special Tools Required
— Measuring Supply Pump Delivery
— Measuring Return Rate from Supply Pump
— Measuring Leakage from Pressure Limiter
— Measuring Return Rate from Injector
— Bleeding Air from Fuel Circuit
— Testing Leakage in Fuel System
— Handling Reduced Cylinder Mode Operation
— Handling No-Injection Cranking Operation
— Handling Controller Voltage Circuit
– EXHAUST SYSTEM AND PIPING
— Checking Muffler and Muffler Stack for Looseness and Damage
— Checking Muffler Function
— Checking Installed Condition of Cylinder Head and Manifolds
— Checking Engine Piping for Damage and Looseness
— Air Intake and Exhaust Systems
— Cooling System
— Fuel System
– BELTS
— Air Conditioner Compressor Belt
— Testing
— Adjusting
— Alternator Belt
— Replacing
– DIRECTIONAL LEVER
— Special Tool Required
— Checking Operating Effort
— Checking Stroke
– POWER TRAIN OIL PRESSURES
— Oil Pressure Measuring Points And Gauges
— Special Tools Required
— Measuring Transmission Hydraulic Operating Pressures
— Transmission Main Relief Pressure
— Torque Converter Relief Pressure (Inlet)
— Torque Converter Outlet Pressure
— Lockup Clutch Pressure (Lockup Clutch Specification)
— F (Forward) Clutch Pressure
— R (Reverse) Clutch Pressure
— 1st Clutch Pressure
— 2nd Clutch Pressure
— 3rd Clutch Pressure
—- 9. After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition.
— 4th Clutch Pressure
— Lubrication Pressure
— Adjusting Power Train Oil Pressures
— Transmission Main Relief Valve
– TRANSMISSION
— Speed Sensor
— Flushing Transmission System
— Torque Converter, Transmission, and Hydraulic Circuit
— Moving the Machine if Transmission Valve Fails
— Moving the Machine
— Special Tool Required
– STEERING SYSTEM
— Steering Stop Valve
— Testing
— Adjusting
— Steering Wheel
— Special Tool Required
— Measuring Play in Steering Wheel
— Measuring Operating Effort of Steering Wheel
— Measuring Operating Time of Steering Wheel
— Steering Oil Pressure
— Special Tools Required
— Measuring Steering Relief Pressure
— Measuring Steering Pilot Circuit Pressure
— Adjusting Steering Relief Pressure
— Adjusting Steering Control Circuit Pressure
— Bleeding Air from Steering Circuit
— Bleeding Air from Steering Pump
— Bleeding Air from Steering Cylinder Circuit
— Steering Column Lock Lever
– HYDRAULIC DRIVE FAN
— Special Tools Required
— Measurement Conditions:
— Measuring Fan Speed
— Measuring Fan Drive Oil Pressure
— Bleeding Air from Hydraulic Drive Fan Circuit
— Special Tools Required
— Bleeding Air From Fan Pump
— Bleeding Air from Fan Motor Circuit
– WHEEL BRAKE SYSTEM
— Measuring Brake Performance
— Measurement Conditions
— Accumulator Charge
— Special Tools Required
— Measurement Conditions
— Measuring
— Adjusting
— Measuring Brake Oil Pressure
— Special Tools Required
— Brake Test Kit S
— Testing Wear of Wheel Brake Disc
— Special Tools Required
— Bleeding Air from Brake Circuit
— Releasing Residual Pressure in Brake Accumulator Circuit
– PARKING BRAKE SYSTEM
— Testing Parking Brake Performance
— Measurement Conditions
— Measuring Parking Brake Oil Pressure
—- Special Tools Required
—- Measurement Conditions
— Checking Wear of Parking Brake Disc
—- Special Tools Required
— Releasing Parking Brake Manually
– WORK EQUIPMENT SYSTEM
— Work Equipment Control Levers
— Special Tools Required
— Measurement Conditions
— Measuring Operating Effort
— Measuring Stroke
— PPC Oil Pressure
— Special Tools Required
— Measurement Condition
— Measuring PPC Valve Basic Pressure
— Measuring PPC Valve Output Pressure
— Replacing PPC Relief Valve
— Work Equipment Hydraulic Pressure
— Special Tools Required
— Measurement Condition
— Combination of Actuator And Valve
— Preparation Work
— Measuring Work Equipment Relief Pressure
— Measuring Unload Pressure
— Measuring Work Equipment LS Differential Pressure
— Adjusting Work Equipment Relief Pressure
— Adjusting LS Differential Pressure
— Bleeding Air from Work Equipment Circuit
— From Work Equipment Pump (Piston Pump)
— From Hydraulic Cylinder
— Releasing Residual Pressure in Work Equipment Circuit
— From Circuit Between Hydraulic Cylinders and Control Valve
— From ECSS (Travel Damper) Circuit
— Work Equipment Positioners
— Bucket Positioner
—- Measurement Conditions
—- Testing
—- Adjusting Clearance
—- Adjusting Mounting Position (Stopping Position)
— Boom Kickout
—- Testing
—- Adjusting
— Proximity Switch Operation Pilot Lamp
– ELECTRICAL SYSTEM TROUBLESHOOTING
— Procedure for Testing Diodes
— When Using Digital Type Circuit Tester
— When Using Analog Type Circuit Tester
— Preparation for Troubleshooting Electric System
— Machine Monitor
— Transmission Controller
— Work Equipment Controller (if equipped)
— KOMTRAX Terminal
— Sensors
— Boost Pressure and Temperature Sensor (BOOST PRESS & IMT)
— Supply Pump IMV Solenoid (FUEL REGULATOR)
— Common Rail Pressure Sensor (FUEL RAIL PRESS)
— Engine Coolant Temperature Sensor (COOLANT TEMP)
– KOMTRAX TERMINAL SYSTEM
— Terminal Installed at Plant Before Shipment
— Terminal Retrofitted Machine After Shipment
— Starting Operation
— Station Opening Check in Machine Side
— Application for the Start of Use
—- Request for Orbcomm Terminal Activation Form
— Komtrax Terminal Lamps
— Checking Antennas
— Checking Terminal LED Displays
— Display Contents of 7-segment And Dot For CPU
– MACHINE MONITOR SYSTEM
— Adjusting Machine Monitor
— Adjusting for Replaced, Reassembled, or Added Sensor/Controller
— Adjustment for User’s Needs
— Special Functions of Machine Monitor (EMMS)
— Normal and Special Functions of Machine Monitor
— Functions and Flow of Service Mode
— Operator Mode
— Service Meter/Clock Display Function (1)
— Load Meter Function (2) (if equipped)
— Odometer Display Function (3)
— Maintenance Monitoring Function (4)
—- 1. Filter, oil replacement time display (automatic display)
—- 2. Resetting replacement time (selection menu)
— Telephone Number Input Function (5)
— Language Selection Function (6)
— Monitor Brightness Adjustment Function (7)
— Time Adjustment Function (8)
— Travel Speed/Engine Speed Display Selecting Function (9)
— Travel Speed/Engine Speed Display/Non-Display Selecting Function (10)
— Action Code Display Function (11)
—- Action Codes and Actions Alerted to Operator
— Failure Code Display Function (12)
— Service Mode
— Switching to Service Mode and Screen Display (1)
— Electrical System Fault History Display Function (ELECTRIC FAULT) (2)
— Mechanical System Fault History Display Function (MACHINE FAULT) (3)
— Real-Time Monitoring Function (REAL-TIME MONITOR) (4)
— Real-Time Monitoring Code Tables
—- Monitor Panel (Machine Monitor System)
—- MON (Mechanical Monitor System)
—- Transmission (Transmission Controller System)
—- TM: Detailed Data for Input and Output Signals (Transmission Controller System)
— WRK (Work Equipment Controller Display)
— ENG (Engine Controller System)
— Engine Reduced-Cylinder Function (CYLINDER CUT-OUT) (5)
— No-Injection Cranking Function (6)
— Adjustment Function (TUNING) (7)
—- Adjustment Function
—- Adjustment of Transmission ECMV Current (7-1)
—- Setting of Transmission Initial Learning (7-2)
—- Adjustment of Transmission L Mode Gearshift Point (7-3)
—- Adjustment of Lift Arm Angle Sensor (Raise) (for EPC lever) (7-4)
—- Adjustment of Lift Arm Raise Lever and Variations in the Dead Zone of EPC (7-5)
—- Adjustment of Lift Arm Lower (Float) Lever and Variations in the Dead Zone of EPC (7-6)
—- Adjustment of Bucket Tilt Lever and Variations in the Dead Zone of EPC (7-7)
—- Adjustment of Bucket Dump EPC Starting Current (7-8)
—- Adjustment of 3-spool Valve EPC Cylinder Extraction Lever and Variations in the Dead Zone of EPC (7-9)
—- Adjustment of 3-spool valve EPC Cylinder Retraction Lever and Variations in the Dead Zone of EPC (7-10)
—- Adjustment of Joystick Steering Right Lever and Variations at EPC Starting Point (7-11)
—- Adjustment of Joystick Steering Left Lever and Variations at EPC Starting Point (7-12)
—- Modification of Lift Arm Lever Pattern (7-13)
—- Modification of Bucket Lever Pattern (7-14)
—- Adjustment of Lift Arm Lower Stop Modulation (7-15)
—- Adjustment of Pump Cutoff Pressure in Lift Arm Raise (7-16)
—- Adjustment of Lift Arm Angle Sensor (Raise) (7-17)
—- Adjustment of Lift Arm Angle Sensor (Lower) (7-18)
—- Adjustment of 2-stage Low Idle Throttle Position (7-19)
—- Adjustment of Interval of Fan Automatic Reverse Operation (Automatic Reverse Fan) (7-20)
—- Adjustment of Continuance of Fan Automatic Reverse Operation (Automatic Reverse Fan) (7-21)
— Maintenance Monitoring Function (8)
—- Changing Maintenance Interval Time (8-1)
—- Selecting Enabling or Disabling Timer by Item (8-2)
—- Changing Set Default Value (8-3)
—- Selecting between Timer Stop for All Items and Enable by Item (8-4)
— Operating Information Display Function (OPERATION INFO) (9)
—- Selecting Menu
— Optional Device Selecting Function (10)
—- Optional Component Setting table
—- Change or Settlement for BOOM TYPE OPTION SELECT (10-1)
—- Option Setting/Not Setting Selection (10-2)
—- Setting Tire Deflection Option (10-3)
—- Storing Option Selection (10-4)
— Machine Serial Number Input Function (11)
— Model Select Function (12)
—- Implementing the Model Change
—- Storing Model Change (12-2)
— Initialize Function (13)
– PM-CLINIC INSPECTION TABLE
40 TROUBLESHOOTING
– POINTS TO REMEMBER WHEN TROUBLESHOOTING
– SEQUENCE OF EVENTS IN TROUBLESHOOTING
– PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
— Precautions when Handling Electrical Equipment
— Handling Electronic Control Unit
— Points to Remember when Troubleshooting Electrical Circuits
– ELECTRIC WIRE CODE
— Classification by Thickness
— Classification by Color and Code
— How to Read Electric Wire Code
— Type, Symbol, and Material
— Dimensions
– HANDLING HYDRAULIC EQUIPMENT
– CHECKS BEFORE TROUBLESHOOTING
— Categories and Method of Using Troubleshooting Charts
— Troubleshooting Individual Electrical Circuits
— Chart Use
— Chart Tips
— Troubleshooting Individual Hydraulic Circuits
– CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
— X-Type Connectors
— SWP-Type Connectors
— M-Type Connectors
— S-Type Connectors
— MIC-Type Connectors
— AMP040-Type Connectors
— AMP070-Type Connectors
— AMP Connector
— L-Type Connector
— PA-Type Connector
— Bendix (MS) Connector
— KES1 (Automobile) Connectors
— F-Type Connector
— Connectors for Relay (Socket-Type)
— HD30 Series Connectors
— DT Series Connectors
— DTM Series Connectors
— DTHD Series Connectors
— DTP Series Connectors
— DRC26 Series Connectors
— DRC12, 16 Series Connectors
— AMP Connectors for Pump Controller (CH700)
— BOSCH Connectors for Engine
— SUMITOMO Connectors for Engine
— CANNON Connector for Engine
— AMP Connectors for Engine
— FRAMATOME Connectors for Engine
— PACKARD Connectors for Engine
— DT Series Connectors for Engine
– T-BRANCH BOX and T-BRANCH ADAPTER TABLE
– MODE CHART
– INFORMATION CONTAINED IN TESTING PROCEDURES
– TROUBLESHOOTING BY FAILURE CODE
— Failure Code Table
– FUSE BOX AND SLOW-BLOW FUSES
— Connection Table
— Fuse Box 1
— Fuse Box 2
— Slow-Blow Fuses
– FAILURE CODES
– 1500L0
— TORQFLOW Transmission: Double Meshing
– 15SAL1
— ECMV F Clutch: When Command Current is OFF, Fill Signal is ON
– 15SALH
— ECMV F Clutch: When Command Current is ON, Fill Signal is OFF
– 15SBL1
— ECMV R Clutch: When Command Current is OFF, Fill Signal is ON
– 15SBLH
— ECMV R Clutch: When Command Current is ON, Fill Signal is OFF
– 15SEL1
— ECMV 1st Clutch: When Command Current is OFF, Fill Signal is ON
– 15SELH
— ECMV 1st Clutch: When Command Current is ON, Fill Signal is OFF
– 15SFL1
— ECMV 2nd Clutch: When Command Current is OFF, FIll Signal is ON
– 15SFLH
— ECMV 2nd Clutch: When Command Current is ON, Fill Signal is OFF
– 15SGL1
— ECMV 3rd Clutch: When Command Current is OFF, Fill Signal is ON
– 15GLH
— ECMV 3rd Clutch: When Command Current is ON, Fill Signal is OFF
– 15SHL1
— ECMV 4th Clutch: When Command Current is OFF, Fill Signal is ON
– 15SHLH
— ECMV 4th Clutch: When Command Current is ON, Fill Signal is OFF
– 2F00MA
— Parking Brake: Malfunction
– 2G43ZG
— Rear Accumulator: Low Oil Pressure
– 44K0L4
— Bucket Positioner: ON/OFF Signals Disagree
– AA1ANX
— Air Cleaner: Clogging
– AB00L6
— Alternator: Signal Disagrees with Operating State of Engine
– AB00MA
— Alternator: Malfunction
– B@BAZG
— Engine: Rotation Derating by Low Engine Oil Pressure
– B@BAZK
— Engine Oil: Low Level
– B@BCNS
— Engine Coolant: Overheating
– B@BCZK
— Engine Coolant: Low Level
– B@BEBF
— Water in Fuel Error
– B@C7NS
— Brake Oil: Overheating
– b@CENS
— Torque Converter Oil: Overheating
– B@CENS
— Torque Converter Oil: Overheating
– B@HANS
— Hydraulic Oil: Overheating
– CA111
— Abnormality in Engine Controller
– CA115
— Engine Ne or Bkup Speed Sensor Error
– CA122
— Charge Pressure Sensor High Error
– CA123
— Charge Pressure Sensor Low Error
– CA131
— Throttle Sensor High Error
– CA132
— Throttle Sensor Low Error
– CA144
— Coolant Temperature Sensor High Error
– CA145
— Coolant Temperature Sensor Low Error
– CA153
— Charge Temperature Sensor High Error
– CA154
— Charge Temperature Sensor Low Error
– CA155
— Derating of Speed by Abnormally High Charge Temperature
– CA187
— Sensor Power Supply 2 Low Error
– CA221
— Atmospheric Pressure Sensor High Error
– CA222
— Atmospheric Pressure Sensor Low Error
– CA227
— Sensor Power Supply 2 High Error
– CA234
— Engine Overspeed
– CA238
— Ne Speed Sensor Power Supply Error
– CA271
— IMV/PCV1 Short Circuit
– CA272
— IMV/PCV1 Disconnection
– CA322
— Injector #1 Open/Short Error
– CA323
— Injector #5 Open/Short Error
– CA324
— Injector #3 Open/Short Error
– CA325
— Injector #6 Open/Short Error
– CA331
— Injector #2 Open/Short Error
– CA332
— Injector #4 Open/Short Error
– CA342
— Calibration Code Inconsistency
– CA351
— Injectors Drive Circuit Error
– CA352
— Sensor Power Supply 1 Low Error
– CA386
— Sensor Power Supply 1 High Error
– CA428
— Abnormally High Level in Water Sensor
– CA429
— Abnormally Low Level in Water Sensor
– CA431
— Idle Validation Switch Error
– CA432
— Idle Validation Action Error
– CA435
— Engine Oil Pressure Switch Error
– CA441
— Battery Voltage Low Error
– CA442
— Battery Voltage High Error
– CA449
— Common Rail Pressure High Error 2
– CA451
— Common Rail Pressure Sensor High Error
– CA452
— Common Rail Pressure Sensor Low Error
– CA488
— Derating of Torque by Abnormally High Charge Temperature
– CA553
— Common Rail Pressure High Error 1
– CA559
— Supply Pump Pressure Very Low Error 1
– CA689
— Engine Ne Speed Sensor Error
– CA731
— Engine Bkup Speed Sensor Phase Error
– CA757
— All Continuous Data Lost Error
– CA778
— Engine Bkup Speed Sensor Error
– CA1633
— KOMNET Datalink Timeout Error
– CA2185
— Throttle Sensor Power Supply Voltage High Error
– CA2186
— Throttle Sensor Power Supply Voltage Low Error
– CA2249
— Supply Pump Pressure Very Low Error 2
– CA2311
— Abnormality in IMV Solenoid
– CA2555
— Intake Heater Relay Disconnection Error
– CA2556
— Intake Heater Relay Short Circuit Error
– D150KA
— Emergency Steering Relay: Disconnection
– D150KB
— Emergency Steering Relay: Short Circuit
– D150KY
— Emergency Steering Relay: Short Circuit with Power Supply Line
– D160KA
— Backup Lamp Relay: Disconnection
– D160KB
— Backup Lamp Relay: Short Circuit
– D191KA
— Joystick Steering Neutral Safety Relay: Disconnection
– D191KB
— Joystick Steering Neutral Safety Relay: Short Circuit
– D191KY
— Joystick Steering Neutral Safety Relay: Short Circuit with Power Supply Line
– D192KA
— ECSS Solenoid: Disconnection
– D192KB
— ECSS Solenoid: Short Circuit
– D192KY
— ECSS Solenoid Relay: Short Circuit with Power Supply Line
– D193KA
— Joystick Steering Solenoid Cut Relay: Disconnection
– D193KB
— Joystick Steering Solenoid Cut Relay: Short Circuit
– D193KY
— Joystick Steering Solenoid Cut Relay: Short Circuit with Power Supply Line
– D5ZHKA
— Terminal C Signal: Disconnection
– D5ZHKB
— Terminal C Signal: Short Circuit
– D5ZHKZ
— Terminal C Signal: Disconnection or Short Circuit
– D5ZHL6
— Terminal C Signal: Signal Does Not Match Engine Running or Stopped State
– DA80L4
— Auto-Grease Controller: ON/OFF Signals Disagree
– DAF3KK
— Machine Monitor: Low Source Voltage (input)
– DAF5KP
— Machine Monitor: Low Output Voltage
– DAFRKR
— Machine Monitor: CAN Defective Communication
– DAQ0KK
— Transmission Controller: Low Source Voltage
– DAQ0KT
— Transmission Controller: Abnormality in Controller
– DAQ2KK
— Transmission Controller Load Power Supply Line: Low Source Voltage (input)
– DAQ9KQ
— Transmission Controller: Disagreement of Model Selection Signals
– DAQRKR
— CAN Communication with Transmission Controller: Defective Communication
– DAQRMA
— Transmission Controller Option Setting: Malfunction
– DB2RKR
— CAN Communication with Engine Controller: Defective Communication
– DB90KK
— Work Equipment Controller: Low Source Voltage (input)
– DB90KT
— Work Equipment Controller: Abnormality in Controller
– DB92KK
— Work Equipment Controller Load Power Supply Line: Low Source Voltage (input)
– DD95KX
— Work Equipment Controller Power Supply Output: Out-of-Input Signal Range
– DB99KQ
— Work Equipment Controller: Disagreement in Model Selection Signals
– DB9RKR
— CAB Communication with Work Equipment Controller: Defective Communication
– DB9RMA
— Work Equipment Controller Option Setting: Malfunction
– DB9RMC
— CAN Communication: Defective Operation
– DD15LD
— Switch (Panel Switch 1 n): Switch is Pressed for Long Time
– DD16LD
— Switch (Panel Switch 2 ‡): Switch is Pressed for Long Time
– DD17LD
— Switch (Panel Switch 3 <): Switch is Pressed for Long Time - DD18LD -- Switch (Panel Switch 4 >): Switch is Pressed for Long Time
– DD1ALD
— Remote Positioner Raise/Lower Set Switch (raise): Switch is Pressed for Long Time
– DD1BLD
— Remote Positioner Raise/Lower Set Switch (lower): Switch is Pressed for Long Time
– DD1CLD
— Load Meter Subtotal Switch: Switch is Pressed for Long Time
– DD1FLD
— Load Meter Mode Selector Switch (A/B): Switch is Pressed for Long Time
– DD1GLD
— Load Meter Mode Selector Switch (+/-): Switch is Pressed for Long Time
– DD1HLD
— Load Meter Display Selector Switch: Switch is Pressed for Long Time
– DD1NLD
— Fan Reverse Switch: Switch is Pressed for Long Time
– DD1NL4
— Fan Automatic Reverse Switch: Switch is Pressed for Long Time
– DDB6L4
— Parking Brake Switch (Neutralizer): ON/OFF Signals Disagree
– DDE5MA
— Emergency Steering Drive Switch: Malfunction
– DDK3KA
— Right FNR Switch: Disconnection
– DDK4KA
— Joystick Steering FNR Switch: Disconnection
– DDK5L4
— Joystick Steering Shift UP/DOWN Switch: ON/OFF Signals Disagree
– DDK6KA
— FNR Lever Switch: Disconnection
– DDK6KB
— FNR Lever Switch: Short Circuit
– DDS5KA
— Steering Pressure Switch: Disconnected
– DDS5KB
— Steering Pressure Switch: Grounded
– DDT0L4
— Shift Mode Selector Switch: ON/OFF Signals Disagree
– DDT4LD
— Transmission Cutoff Set Switch: Switch is Pressed for Long Time
– DDW9LD
— Kickdown Switch: Switch is Pressed for Long Time
– DDWLLD
— Hold Switch: Switch is Pressed Down for Long Time
– DDY0LD
— Load Meter Cancel Switch: Switch is Pressed for Long Time
– DF10KA
— Transmission Shift Lever Switch: Disconnected
– DF10KB
— Transmission Shift Lever Switch: Short Circuit
– DGF1KA
— Transmission Oil Temperature Sensor: Disconnected
– DGF1KB
— Transmission Oil Temperature Sensor: Short Circuit
– DGH2KX
— Hydraulic Oil Temperature Sensor: Out-of-Input Signal Range
– DGR2KA
— Rear Brake Oil Temperature Sensor: Disconnected
– DGR2KX
— Rear Brake Oil Pressure Sensor: Out-of-Input Signal Range
– DGT1KX
— Torque Converter Oil Temperature Sensor: Out-of-Input Signal Range
– DHPCKX
— Lift Arm Cylinder Bottom Pressure Sensor: Out-of-Input Signal Range
– DHPDKX
— Lift Arm Cylinder Head Pressure Sensor: Out-of-Input Signal Range
– DHT1KX
— Transmission Cutoff Pressure Sensor: Out-of-Input Signal
– DHT8KA
— Steering Pump Pressure Sensor: Disconnection
– DHT8KB
— Steering Pump Pressure Sensor: Short Circuit
– DK59KA
— Lift Arm EPC Lever Potentiometer (Main): Disconnection
– DK59KY
— Lift Arm EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line
– DK59L8
— Lift Arm EPC Lever Potentiometer (Main): Analog Signals Disagree
– DK5AKA
— Lift Arm EPC Lever Potentiometer (Sub): Disconnection
– DK5AKY
— Lift Arm EPC Lever Potentiometer (Sub): Short Circuit with Power Supply LIne
– DK5BKA
— Bucket EPC Lever Potentiometer (Main): Disconnection
– DK5BKY
— Bucket EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line
– DK5BL8
— Bucket EPC Lever Potentiometer (Main): Analog Signals Disagree
– DK5CKA
— Bucket EPC Lever Potentiometer (Sub): Disconnection
– DK5CKY
— Bucket EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line
– DK5FKA
— Joystick Steering EPC Lever Potentiometer (Main): Disconnection
– DK5FKY
— Joystick Steering EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line
– DK5GKA
— Joystick Steering EPC Lever Potentiometer (Sub): Disconnection
– DK5GKY
— Joystick Steering EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line
– DK5FL8
— Joystick Steering EPC Lever Potentiometer (Main): Analog Signals Disagree
– DKA0KA
— Lift Arm Angle Sensor: Disconnection
– DKA0KY
— Lift Arm Angle Sensor: Short Circuit with Power Supply Line
– DKA0L0
— Lift Arm Angle Sensor: Double Meshing
– DLT3KA
— Transmission Output Shaft Speed Sensor: Disconnection
– DLT3LC
— Transmission Output Shaft Speed Sensor: Out-of-Input Signal Range
– DT20KB
— Transmission Cutoff Indicator Lamp: Short Circuit
– DUM1KB
— Remote Positioner Raise Set Indicator Lamp: Short Circuit
– DUM2KB
— Remote Positioner Lower Set Indicator Lamp: Short Circuit
– DV00KB
— Alarm Buzzer: Short Circuit
– DW4PKA
— Lift Arm Raise EPC Solenoid: Disconnection
– DW4PKB
— Lift Arm Raise EPC Solenoid: Short Circuit
– DW4PKY
— Lift Arm Raise EPC Solenoid: Short Circuit with Power Supply Line
– DW4QKA
— Lift Arm Lower EPC Solenoid: Disconnection
– DW4QKB
— Lift Arm Lower EPC Solenoid: Short Circuit
– DW4QKY
— Lift Arm Lower EPC Solenoid: Short Circuit with Power Supply Line
– DW4RKA
— Bucket Tilt EPC Solenoid: Disconnection
– DW4RKB
— Bucket Tilt EPC Solenoid: Short Circuit
– DW4RKY
— Bucket Tilt EPC Solenoid: Short Circuit with Power Supply Line
– DW4SKA
— Buck Dump EPC Solenoid: Disconnection
– DW4SKB
— Bucket Dump EPC Solenoid: Short Circuit
– DW4SKY
— Bucket Dump EPC Solenoid: Short Circuit with Power Supply Line
– DW7BKA
— Fan Reverse Solenoid: Disconnection
– DW7BKB
— Fan Reverse Solenoid: Short Circuit
– DW7BKY
— Fan Reverse Solenoid: Short Circuit with Power Supply Line
– DWM1KA
— Work Equipment Neutral Lock Solenoid: Disconnection
– DWM1KB
— Work Equipment Neutral Lock Solenoid: Short Circuit
– DWM1KY
— Work Equipment Neutral Lock Solenoid: Short Circuit with Power Supply Line
– DWN6KA
— Lift Arm Raise Magnet Detent Solenoid: Disconnection
– DWN6KB
— Lift Arm Raise Magnet Detent Solenoid: Short Circuit
– DWN6KY
— Lift Arm Raise Magnet Detent Solenoid: Short Circuit with Power Supply Line
– DWN7KA
— Lift Arm Float Magnet Detent Solenoid: Disconnection
– DWN7KB
— Lift Arm Float Magnet Detent Solenoid: Short Circuit
– DWN7KY
— Lift Arm Float Magnet Detent Solenoid: Short Circuit with Power Supply Line
– DWN8KA
— Bucket Tilt Magnet Detent Solenoid: Disconnection
– DWN8KB
— Bucket Tilt Magnet Detent Solenoid: Short Circuit
– DWN8KY
— Bucket Tilt Magnet Detent Solenoid: Shorted with the Power Source
– DX16KA
— Fan Pump EPC Solenoid: Disconnection
– DX16KB
— Fan Pump EPC Solenoid: Short Circuit
– DX16KY
— Fan Pump EPC Solenoid: Short Circuit with Power Supply Line
– DXH1KA
— Lockup ECMV Solenoid: Disconnection
– DXH1KB
— Lockup ECMV Solenoid: Short Circuit
– DXH1KY
— Lockup ECMV Solenoid: Short Circuit with Power Supply Line
– DXH4KA
— 1st Clutch ECMV Solenoid: Disconnection
– DXH4KB
— 1st Clutch ECMV Solenoid: Short Circuit
– DXH4KY
— 1st Clutch ECMV Solenoid: Short Circuit with Power Supply Line
– DXH5KA
— 2nd Clutch ECMV Solenoid: Disconnection
– DXH5KB
— 2nd Clutch ECMV Solenoid: Short Circuit
– DXH5KY
— 2nd Clutch ECMV Solenoid: Short Circuit with Power Supply Line
– DXH6KA
— 3rd Clutch ECMV Solenoid: Disconnection
– DXH6KB
— 3rd Clutch ECMV Solenoid: Short Circuit
– DXH6KY
— 3rd Clutch ECMV Solenoid: Short Circuit with Power Supply Line
– DXH7KA
— R Clutch ECMV Solenoid: Disconnection
– DXH7KB
— R Clutch ECMV Solenoid: Short Circuit
– DXH7KY
— R Clutch ECMV Solenoid: Short Circuit with Power Supply Line
– DXH8KA
— F Clutch ECMV Solenoid: Disconnection
– DXH8KB
— F Clutch ECMV Solenoid: Short Circuit
– DXH8KY
— F Clutch ECMV Solenoid: Short Circuit with Power Supply Line
– DXHHKA
— 4th Clutch ECMV Solenoid: Disconnection
– DXHHKB
— 4th Clutch ECMV Solenoid: Short Circuit
– DXHHKY
— 4th Clutch ECMV Solenoid: Short Circuit with Power Supply Line
– DXHLKA
— Joystick Steering Right EPC Solenoid: Disconnection
– DXHLKB
— Joystick Steering Right EPC Solenoid: Short Circuit
– DXHLKY
— Joystick Steering Right EPC Solenoid: Short Circuit with Power Supply Line
– DXHMKA
— Joystick Steering Left EPC Solenoid: Disconnection
– DXHMKB
— Joystick Steering Left EPC Solenoid: Short Circuit
– DXHMKY
— Joystick Steering Left EPC Solenoid: Short Circuit with Power Supply Line
– DY30MA
— Motor-Driven Emergency Steering Pump Failure (during Operation of machine)
– DY30MC
— Motor-Driven Emergency Steering Pump Failure (Malfunction in Manual Mode)
– TROUBLESHOOTING: E-MODE
— Troubleshooting Electrical System
— Information in Troubleshooting Table
– E-1
— Engine Does Not Start
– E-2
— Wiper Does Not Operate
– E-3
— Windshield Washer Does Not Operate
– E-4
— Headlamp, Clearance Lamp, Tail Lamp, and License Lamp Do Not Light Up or Go Off
– E-5
— Working Lamp Does Not Light Up or Go Off
– E-6
— Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off
– E-7
— Brake Lamp Does Not Light or It Keeps Lighting Up
– E-8
— Backup Lamp Does Not Light or It Keeps Lighting Up
– E-9
— Backup Buzzer Does Not Sound or It Keeps Sounding
– E-10
— Horn Does Not Sound or It Keeps Sounding
– E-11
— Alarm Buzzer Does Not Sound or It Keeps Sounding
– E-12
— Air Conditioner Does Not Operate or Stop
– E-13
— KOMTRAX System Does Not Work Properly
— Indicator Lamps of KOMTRAX Terminal
– E-14
— When Kickdown Switch is Turned On, Kickdown Operation Does Not Start
– E-15
— When Hold Switch is Pressed, Holding Operation Does Not Start
– E-16
— Transmission Kept in Neutral or Brake Drags when Directional Lever is Operated While Parking Brake is Applied
– E-17
— Transmission Cutoff Mode Cannot Be Set or Reset
– E-18
— Transmission Cutoff Set Cannot be Reset
– E-19
— FN Switch Mode Cannot Be Set or Reset
– E-20
— Fan Reverse Function Cannot Be Used or Reset
– E-21
— Discharge from Loader Pump Does Not Rise from Minimum Level
– E-22
— ECSS Function Cannot Be Used or Reset
– E-23
— When Parking Brake is Turned On, Parking Brake Indicator Lamp Does Not Light Up
– E-24
— When Emergency Brake Operates, Brake Oil Pressure Caution Lamp Does Not Operate
– E-25
— Air Cleaner Clogging Indicator Lamp Does Not Light Up
– E-26
— Radiator Coolant Level Caution Lamp Does Not Light Up
– E-27
— Hydraulic Oil Temperature Gauge Does Not Rise and Hydraulic Oil Temperature Caution Lamp Does Not Light Up
– E-28
— Torque Converter Oil Temperature Gauge Does Not Rise and Torque Converter Oil Temperature Caution Lamp Does Not Light Up
– E-29
— Steering Oil Pressure Caution Lamp Does Not Light Up
– E-30
— Abnormality in Switch (n) (Panel Switch 1) Input
– E-31
— Abnormality in Switch (‡) (Panel Switch 2) Input
– E-32
— Abnormality in Switch (<) (Panel Switch 3) Input - E-33 -- Abnormality in Switch (>) (Panel Switch 4) Input
– TROUBLESHOOTING: H-MODE
— Troubleshooting Hydraulic and Mechanical Systems
— Using Troubleshooting Chart
— Failure Codes and Causes Table
– H-1
— Machine Does Not Start
– H-2
— Torque Converter Lockup is Not Switched OFF (Engine Stalls)
– H-3
— Torque Converter Lockup is Not Switched ON
– H-4
— Travel Speed is Slow, Thrusting Force is Weak, Uphill Traveling Power is Weak, Gear is Not Shifted
– H-5
— Large Shocks When Starting and Shifting Gears
– H-6
— Large Time Lag When Starting and Shifting Gear
– H-7
— Torque Converter Oil Temperature is High
– H-8
— Steering Does Not Turn
– H-9
— Steering Does Not Turn (Joystick Steering, if equipped)
– H-10
— Steering Response is Poor
– H-11
— Steering, Turning Response is Poor (Joystick Steering, if Equipped)
– H-12
— Steering is Heavy
– H-13
— When Machine Turns, It Shakes or Jerks
– H-14
— When Machine Turns, It Shakes or Jerks (Joystick Steering, if Equipped)
– H-15
— Wheel Brake Does Not Work or Does Not Work Well
– H-16
— Wheel Brake is Not Released or It Drags
– H-17
— Parking Brake Does Not Work or Does Not Work Well
– H-18
— Parking Brake is Not Released or It Drags
– H-19
— Lift Arm Does Not Rise
– H-20
— Lift Arm Speed is Low or Rising Force is Insufficient
– H-21
— When Rising, Lift Arm Starts to Move Slowly at a Specific Height
– H-22
— Lift Arm Cylinder Cannot Hold Down Bucket (Bucket Floats)
– H-23
— Hydraulic Drifts of the Lift Arm Are Large
– H-24
— Lift Arm Wobbles During Operation
– H-25
— Bucket Does Not Tilt Back
– H-26
— Bucket Speed is Low or Tilting-Back Force Is Insufficient
– H-27
— Bucket Starts to Operate Slowly in the Midst of Tilting Back
– H-28
— Bucket Cylinder Cannot Hold Down the Bucket
– H-29
— Hydraulic Drifts of the Bucket Are Large
– H-30
— Bucket Wobbles During Travel with Load
– H-31
— Lift Arm and Bucket Control Levers Do Not Move Smoothly and Are Heavy
– H-32
— During Operation of Machine, Engine Speed Drops Remarkably or Engine Stalls
– H-33
— Large Shocks When Work Equipment Starts and Stops
– H-34
— When Work Equipment Circuit is Relieved Singly, Other Work Equipment Moves
– H-35
— ECSS Does Not Operate; Pitching and Bouncing Occur
50 DISASSEMBLY AND ASSEMBLY
– HOW TO READ THIS MANUAL
— Removal and Installation of Assemblies
— Disassembly and Assembly of Assemblies
– COATING MATERIALS LIST
– SPECIAL TOOLS LIST
– SKETCHES OF SPECIAL TOOLS
– CONNECTOR REPAIR PROCEDURES
— Stripping Insulation
— Wire Inspection
— Contact Terminal Removal (HD30 Type)
— Crimping Contact Terminal (HD30 Type)
— Insertion Of Contact Terminal (HD30 Type)
— Contact Terminal Removal (DT Type)
— Crimping Contact Terminal (DT Type)
— Insertion Of Contact Terminal (DT Type)
– ENGINE AND COOLING SYSTEM
— Alternator
— Crankshaft
— Camshaft
— Engine Front Seal
— Engine Oil Cooler
— Engine Rear Seal
— Starting Motor
— Thermostat
— Turbocharger
— Water Pump
— Cylinder Head
— Removal
— Installation
— Engine Hood
— Removal
— Installation
— Radiator
— Removal
— Installation
— Air Aftercooler
— Removal
— Installation
— Hydraulic Oil Cooler
— Removal
— Installation
— Engine
— Removal
— Installation
— Cooling Fan and Fan Motor
— Removal
— Installation
– FUEL SUPPLY SYSTEM
— Fuel Supply Pump
— Removal
— Installation
— Fuel Injector
— Removal
— Installation
— Fuel Tank
— Removal
— Installation
– POWER TRAIN
— Torque Converter and Transmission Assembly
— Removal
— Installation
— Torque Converter (Standard Specification)
— Disassembly
— Assembly
— Torque Converter (Lockup Specification)
— Disassembly
— Assembly
— Transmission
— Disassembly
— Assembly
— Clutch Pack
— Forward and Reverse Clutch Pack: Disassembly
— 1st and 4th Clutch Pack: Disassembly
— 2nd and 3rd Gear Clutch Pack: Disassembly
— Forward and Reverse Clutch Pack: Assembly
— 1st and 4th Clutch Pack: Assembly
— 2nd and 3rd Clutch Pack: Assembly
— Parking Brake
— Disassembly
— Assembly
— Front Axle
— Removal
— Installation
— Rear Axle
— Removal
— Installation
— Axle Housing
— Disassembly
— Assembly
— Differential Assembly
— Disassembly
— Assembly
– STEERING SYSTEM
— Steering Valve Assembly
— Removal
— Installation
– BRAKING SYSTEM
— Parking Brake Discs and Plates
— Removal
— Installation
– UNDERCARRAGE AND FRAME
— Center Hinge Pin
— Removal
— Installation
— Counterweight
— Removal
— Installation
– HYDRAULIC SYSTEM
— Work Equipment Control Valve
— Removal
— Installation
— Power Train Pump and Work Equipment Pump Assembly
— Removal
— Installation
— Steering Pump And Cooling Fan Pump Assembly
— Removal
— Installation
— Hydraulic Tank
— Removal
— Installation
– WORK EQUIPMENT
— Work Equipment Assembly
— Removal
— Installation
— Hydraulic Cylinder
— Disassembly
— Assembly
– CAB AND ATTACHMENTS
— Cab and Floor Frame
— Removal
— Installation
— Cab Glass (Stuck Glass)
— Removal
— Installation
— Operator Seat Assembly (Standard Specification) (ISRING HAUSEN)
— Disassembly
— Assembly
— Operator Seat Assembly (GRAMMER)
— Upper Seat
— Suspension
– AIR CONDITIONER UNIT ASSEMBLY
— Removal
— Installation
– ELECTRICAL SYSTEM
— Engine Controller Assembly
— Removal
— Installation
90 DIAGRAMS AND SCHEMATICS
– AUTOMATIC GREASING
— Auto-Grease Circuit Diagram
– HYDRAULIC SYSTEM
— Power Train Hydraulic Circuit Diagram
— Without Lockup Clutch
— With Lockup Clutch
— Hydraulic Circuit Diagram
– ELECTRICAL SYSTEM
— Machine Monitor System Circuit Diagram
— Transmission Controller System Circuit Diagram
— Work Equipment Controller System Diagram
— Work Equipment Controller System Electrical Circuit Diagram
— Electrical Circuit Diagram (1/14)
— Electrical Circuit Diagram (2/14)
— Electrical Circuit Diagram (3/14)
— Electrical Circuit Diagram (4/14)
— Electrical Circuit Diagram (5/14)
— Electrical Circuit Diagram (6/14)
— Electrical Circuit Diagram (7/14)
— Electrical Circuit Diagram (8/14)
— Electrical Circuit Diagram (9/14)
— Electrical Circuit Diagram (10/14)
— Electrical Circuit Diagram (11/14)
— Electrical Circuit Diagram (12/14)
— Electrical Circuit Diagram (13/14)
— Electrical Circuit Diagram (14/14)
— Connector List and Stereogram
— Chassis
— Engine and Transmission
— Operator’s Compartment