Service manual Komatsu WA600-6R 65001 & Up | SEN02211-08

Komatsu WA600-6R 65001 & Up SEN02211-08 (Preview)

COVER

00 INDEX AND FOREWORD
– INDEX
— COMPOSITION OF SHOP MANUAL
— TABLE OF CONTENTS
– FOREWORD AND GENERAL INFORMATION
— SAFETY NOTICE
— HOW TO READ THE SHOP MANUAL
— EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
— HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
— HANDLING OF CONNECTORS NEWLY USED FOR ENGINES
— HOW TO READ ELECTRIC WIRE CODE
— PRECAUTIONS WHEN CARRYING OUT OPERATION
— METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER
— STANDARD TIGHTENING TORQUE TABLE
— CONVERSION TABLE
01 SPECIFICATION
– SPECIFICATION AND TECHNICAL DATA
— SPECIFICATION DIMENSION DRAWING
— SPECIFICATIONS
— WEIGHT TABLE
— TABLE OF FUEL, COOLANT AND LUBRICANTS
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
– ENGINE AND COOLING SYSTEM
— ENGINE MOUNT AND TRANSMISSION MOUNT
— DAMPER
— COOLING SYSTEM
— COOLING FAN PUMP
— COOLING FAN MOTOR
– POWER TRAIN, PART 1
— POWER TRAIN
— POWER TRAIN SYSTEM DIAGRAM
— TORQUE CONVERTER AND TRANSMISSION PIPING DIAGRAM
— TORQUE CONVERTER
— MODULATION CLUTCH
— TORQUE CONVERTER REGULATOR VALVE
— TRANSMISSION
— TRANSFER
— TRANSMISSION CONTROL VALVE
— ECMV
— MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE
— LUBRICATION RELIEF VALVE
– POWER TRAIN, PART 2
— TORQUE CONVERTER OIL COOLER
— TORQUE CONVERTER OIL FILTER
— DRIVE SHAFT
— CENTER SUPPORT
— AXLE
— DIFFERENTIAL
— LIMITED SLIP DIFFERENTIAL
— FINAL DRIVE
– STEERING SYSTEM
— STEERING PIPING DIAGRAM
— STEERING COLUMN
— JOYSTICK STEERING LEVER LINKAGE
— JOYSTICK EPC VALVE
— LOCK VALVE
— STEERING VALVE
— ROTARY VALVE
— STEERING CONTROL VALVE
— TWO-WAY RESTRICTOR VALVE
— STOP VALVE
— STEERING PUMP
— STEERING CYLINDER
— Emergency steering piping diagram
— Diverter valve
— Emergency steering pump
– BRAKE SYSTEM
— BRAKE PIPING DIAGRAM
— BRAKE
— BRAKE VALVE
— ACCUMULATOR CHARGE VALVE
— EPC RELIEF VALVE
— ACCUMULATOR (FOR BRAKE)
— SLACK ADJUSTER
— PARKING BRAKE
— PARKING BRAKE SOLENOID VALVE
— EMERGENCY PARKING BRAKE RELEASE VALVE
— BRAKE COOLING PUMP
– UNDERCARRIAGE AND FRAME
— AXLE MOUNT
— CENTER HINGE PIN
– HYDRAULIC SYSTEM, PART 1
— HYDRAULIC PIPING DIAGRAM
— WORK EQUIPMENT CONTROL LEVER LINKAGE
— HYDRAULIC TANK
— WORK EQUIPMENT HYDRAULIC PUMP
– HYDRAULIC SYSTEM, PART 2
— CONTROL VALVE
— CLSS
— EACH FUNCTION AND OPERATION OF EACH VALVE
— ACCUMULATOR (FOR PPC CIRCUIT)
— TRIPLE PUMP
– Work equipment
— Work equipment linkage
— Bucket
— Bucket positioner and boom kick-out
— Work equipment lubrication
— Work equipment cylinder
– CAB AND ITS ATTACHMENTS
— ROPS CAB
— AIR CONDITIONER
– ELECTRICAL SYSTEM, PART 1
— MACHINE MONITOR SYSTEM
— MACHINE MONITOR
– ELECTRICAL SYSTEM, PART 2
— WORK EQUIPMENT CONTROL SYSTEM
— TRANSMISSION CONTROLLER SYSTEM
– ELECTRICAL SYSTEM, PART 3
— ELECTRIC TRANSMISSION CONTROL
— ENGINE STARTING/STOPPING CIRCUIT
— PARKING BRAKE CIRCUIT
— SENSOR
— VHMS CONTROLLER RELATED
— WORK EQUIPMENT ELECTRIC LEVER
20 STANDARD VALUE TABLE
– STANDARD SERVICE VALUE TABLE
— STANDARD SERVICE VALUE TABLE FOR ENGINE
— STANDARD SERVICE VALUE TABLE FOR CHASSIS
30 TESTING AND ADJUSTING
– Testing and adjusting, Part 1
— Tools for testing, adjusting, and troubleshooting
— Measuring engine speed
— Measuring exhaust gas color
— Measuring exhaust temperature
— Adjusting valve clearance
— Testing compression pressures
— Measuring blow-by pressure
— Measuring engine oil pressure
— Measuring intake air (boost) pressure
— Handling fuel system equipment
— Releasing residual pressure in fuel system
— Testing fuel pressures
— Testing return rate and leakage
— Bleeding air from fuel circuit
— Testing leakage in fuel system
— Handling reduced cylinder mode operation
— Handling no-injection cranking operation
— Handling controller voltage circuit

— Replacing and adjusting alternator and air conditioner compressor belt tension
— Adjusting modulation clutch speed sensor and speed sensor
— Measuring directional lever (Steering wheel specification)
— Testing and adjusting power train oil pressure
— Flushing procedure for torque converter and transmission hydraulic circuit
— Method of moving machine when transmission valve is broken
— Adjusting steering stop valve
– Testing and adjusting, Part 2
— Measuring operating effort of AJSS lever (AJSS specification)
— Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification)
— Testing and adjusting steering stopper bolt (AJSS specification)
— Testing and adjusting steering wheel (Steering wheel specification)
— Testing steering oil pressure
— Bleeding air from steering cylinder circuit
— Testing hydraulic drive fan
— Bleeding air from hydraulic drive fan circuit
— Measuring brake pedal
— Measuring brake performance
— Testing and adjusting accumulator charge pressure
— Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas
— Testing wheel brake oil pressure
— Measuring wear of wheel brake disc
— Bleeding air from wheel brake circuit
— Releasing residual pressure in brake accumulator circuit
— Testing parking brake performance

— Measuring parking brake oil pressure
— Testing wear of parking brake disc

— Method of releasing parking brake manually
— Measuring and adjusting work equipment control lever
— Measuring work equipment oil pressure
— Bleeding air from work equipment circuit
— Releasing residual pressure in work equipment circuit
— Moving machine for removing operator cab
— Testing and adjusting bucket positioner
— Testing and adjusting lift arm position detecting lever
— Checking proximity switch operation indication lamp
— Preparations for work on troubleshooting of electric system1
— Procedure for testing diodes
– TESTING AND ADJUSTING, PART 3
— MACHINE MONITOR-BASED ADJUSTMENT AT REPLACEMENT, DISASSEMBLY AND ASSEMBLY, AND ADDITIONAL INSTALLATION FOR EACH SENSOR AND CONTROLLER
— SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS)
– TESTING AND ADJUSTING, PART 4
— VHMS CONTROLLER INITIAL SETTING PROCEDURE
— PRECAUTIONS FOR REPLACING VHMS CONTROLLER
— PM-CLICK INSPECTION TABLE
40 TROUBLESHOOTING
– FAILURE CODE TABLE AND FUSE LOCATIONS
— FAILURE CODES LIST
— FUSE LOCATIONS
– GENERAL INFORMATION ON TROUBLESHOOTING
— POINTS TO REMEMBER WHEN TROUBLESHOOTING
— SEQUENCE OF EVENTS IN TROUBLESHOOTING
— TESTING BEFORE TROUBLESHOOTING
— CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
— INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
— PHENOMENA LOOKING LIKE TROUBLES AND TROUBLESHOOTING NOS.
— CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
— T- BRANCH BOX AND T- BRANCH ADAPTER TABLE
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 1
— FAILURE CODE [1500L0] (TORQFLOW TRANSMISSION : DOUBLE MESHING)
— FAILURE CODE [15B0NX] (TRANSMISSION FILTER: CLOGGED)
— FAILURE CODE [15SAL1] (ECMV F CLUTCH: WHEN COMMAND CURRENT IS OFF, FILL SIGNAL IS ON)
— FAILURE CODE [15SALH] (ECMV F CLUTCH: WHEN COMMAND CURRENT IS ON, FILL SIGNAL IS OFF)
— FAILURE CODE [15SBL1] (ECMV R CLUTCH: WHEN COMMAND CURRENT IS OFF, FILL SIGNAL IS ON)
— FAILURE CODE [15SBLH] (ECMV R CLUTCH: WHEN COMMAND CURRENT IS ON, FILL SIGNAL IS OFF)
— FAILURE CODE [15SEL1] (ECMV (1): WHEN COMMAND CURRENT IS OFF, FILL SIGNAL IS ON)
— FAILURE CODE [15SELH] (ECMV (1): WHEN COMMAND CURRENT IS ON, FILL SIGNAL IS OFF)
— FAILURE CODE [15SFL1] (ECMV (2): WHEN COMMAND CURRENT IS OFF, FILL SIGNAL IS ON)
— FAILURE CODE [15SFLH] (ECMV (2): WHEN COMMAND CURRENT IS ON, FILL SIGNAL IS OFF)
— FAILURE CODE [15SGL1] (ECMV (3): WHEN COMMAND CURRENT IS OFF, FILL SIGNAL IS ON)
— FAILURE CODE [15SGLH] (ECMV (3): WHEN COMMAND CURRENT IS ON, FILL SIGNAL IS OFF)
— FAILURE CODE [15SHL1] (ECMV (4): WHEN COMMAND CURRENT IS OFF, FILL SIGNAL IS ON)
— FAILURE CODE [15SHLH] (ECMV (4): WHEN COMMAND CURRENT IS ON, FILL SIGNAL IS OFF)
— FAILURE CODE [15W0NT] (TRANSMISSION MODULATION CLUTCH: OVERHEATING)
— FAILURE CODE [2F00MA] (PARKING BRAKE: MALFUNCTION)
— FAILURE CODE [2G42ZG] (FRONT ACCUMULATOR: LOW OIL PRESSURE)
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 2
— FAILURE CODE [2G43ZG] (REAR ACCUMULATOR: LOW OIL PRESSURE)
— FAILURE CODE [44K0L4] (BUCKET POSITIONER: ON/OFF SIGNALS DISAGREE)
— FAILURE CODE [A000N1] (OR VHMS_LED DISPLAY: “N2” -> “01”) (ENGINE: OVERRUN)
— FAILURE CODE [AA1ANX] (AIR CLEANER: CLOGGING)
— FAILURE CODE [AB00L6] (ALTERNATOR: SIGNAL DISAGREES WITH OPERATING STATE OF ENGINE)
— FAILURE CODE [AB00MA] (ALTERNATOR: MALFUNCTION)
— FAILURE CODE [B@BAZG] (ENGINE OIL PRESSURE: LOW ERROR)
— FAILURE CODE [B@BAZK] (ENGINE OIL: LOW LEVEL)
— FAILURE CODE [B@BCNS] (ENGINE COOLANT TEMPERATURE: OVERHEATING)
— FAILURE CODE [B@BCZK] (COOLANT: LOW LEVEL)
— FAILURE CODE [B@C7NS] (BRAKE OIL: OVERHEATING)
— FAILURE CODE [b@CENS] (TORQUE CONVERTER OIL: OVERHEATING)
— FAILURE CODE [B@CENS] (TORQUE CONVERTER OIL: OVERHEATING)
— FAILURE CODE [B@GAZK] (BATTERY ELECTROLYTE: LOW LEVEL)
— FAILURE CODE [B@HANS] (HYDRAULIC OIL: OVERHEATING)
— FAILURE CODE [CA111] (ABNORMALITY IN ENGINE CONTROLLER)
— FAILURE CODE [CA115] (ENGINE NE OR BKUP SPEED SENSOR ERROR)
— FAILURE CODE [CA122] (CHARGE (BOOST) PRESSURE SENSOR HIGH ERROR)
— FAILURE CODE [CA123] (CHARGE (BOOST) PRESSURE SENSOR LOW ERROR)
— FAILURE CODE [CA131] (THROTTLE SENSOR HIGH ERROR)
— FAILURE CODE [CA132] (THROTTLE SENSOR LOW ERROR)
— FAILURE CODE [CA135] (ENGINE OIL PRESSURE SENSOR HIGH ERROR)
— FAILURE CODE [CA141] (ENGINE OIL PRESSURE SENSOR LOW ERROR)
— FAILURE CODE [CA144] (COOLANT TEMPERATURE SENSOR HIGH ERROR)
— FAILURE CODE [CA145] (COOLANT TEMPERATURE SENSOR LOW ERROR)
— FAILURE CODE [CA153] (CHARGE (BOOST) TEMPERATURE SENSOR HIGH ERROR)
— FAILURE CODE [CA154] (CHARGE (BOOST) TEMPERATURE SENSOR LOW ERROR)
— FAILURE CODE [CA187] (SENSOR POWER SUPPLY 2 LOW ERROR)
— FAILURE CODE [CA212] (ENGINE OIL TEMPERATURE SENSOR HIGH ERROR)
— FAILURE CODE [CA213] (ENGINE OIL TEMPERATURE SENSOR LOW ERROR)
— FAILURE CODE [CA221] (ATMOSPHERIC PRESSURE SENSOR HIGH ERROR)
— FAILURE CODE [CA222] (ATMOSPHERIC PRESSURE SENSOR LOW ERROR)
— FAILURE CODE [CA227] (SENSOR POWER SUPPLY 2 HIGH ERROR)
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 3
— FAILURE CODE [CA234] (ENGINE OVERSPEED)
— FAILURE CODE [CA238] (NE SPEED SENSOR POWER SUPPLY ERROR)
— FAILURE CODE [CA263] (FUEL TEMPERATURE SENSOR HIGH ERROR)
— FAILURE CODE [CA265] (FUEL TEMPERATURE SENSOR LOW ERROR)
— FAILURE CODE [CA271] (PCV1 SHORT CIRCUIT)
— FAILURE CODE [CA272] (PCV1 DISCONNECTION)
— FAILURE CODE [CA273] (PCV2 SHORT CIRCUIT)
— FAILURE CODE [CA274] (PCV2 DISCONNECTION)
— FAILURE CODE [CA322] (INJECTOR #1 OPEN/SHORT ERROR)
— FAILURE CODE [CA323] (INJECTOR #5 OPEN/SHORT ERROR)
— FAILURE CODE [CA324] (INJECTOR #3 OPEN/SHORT ERROR)
— FAILURE CODE [CA325] (INJECTOR #6 OPEN/SHORT ERROR)
— FAILURE CODE [CA331] (INJECTOR #2 OPEN/SHORT ERROR)
— FAILURE CODE [CA332] (INJECTOR #4 OPEN/SHORT ERROR)
— FAILURE CODE [CA342] (CALIBRATION CODE INCONSISTENCY)
— FAILURE CODE [CA351] (INJECTORS DRIVE CIRCUIT ERROR)
— FAILURE CODE [CA352] (SENSOR POWER SUPPLY 1 LOW ERROR)
— FAILURE CODE [CA386] (SENSOR POWER SUPPLY 1 HIGH ERROR)
— FAILURE CODE [CA431] (IDLE VALIDATION SWITCH ERROR)
— FAILURE CODE [CA432] (IDLE VALIDATION ACTION ERROR)
— FAILURE CODE [CA441] (BATTERY VOLTAGE LOW ERROR)
— FAILURE CODE [CA442] (BATTERY VOLTAGE HIGH ERROR)
— FAILURE CODE [CA449] COMMON RAIL PRESSURE HIGH ERROR 2
— FAILURE CODE [CA451] (COMMON RAIL PRESSURE SENSOR HIGH ERROR)
— FAILURE CODE [CA452] (COMMON RAIL PRESSURE SENSOR LOW ERROR)
— FAILURE CODE [CA553] (COMMON RAIL PRESSURE HIGH ERROR 1)
— FAILURE CODE [CA559] (SUPPLY PUMP PRESSURE VERY LOW ERROR)
— FAILURE CODE [CA689] (ENGINE NE SPEED SENSOR ERROR)
— FAILURE CODE [CA731] (ENGINE BKUP SPEED SENSOR PHASE ERROR)
— FAILURE CODE [CA757] (ALL CONTINUOUS DATA LOST ERROR)
— FAILURE CODE [CA778] (ENGINE BKUP SPEED SENSOR ERROR)
— FAILURE CODE [CA1633] (KOMNET DATALINK TIMEOUT ERROR)
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 4
— FAILURE CODE [CA2185] (THROTTLE SENSOR SUPPLY VOLTAGE HIGH ERROR)
— FAILURE CODE [CA2186] (THROTTLE SENSOR POWER SUPPLY LOW ERROR)
— FAILURE CODE [CA2249] (SUPPLY PUMP PRESSURE VERY LOW ERROR 2)
— FAILURE CODE [CA2555] (INTAKE HEATER RELAY DISCONNECTION ERROR)
— FAILURE CODE [CA2556] (INTAKE HEATER RELAY SHORT CIRCUIT ERROR)
— FAILURE CODE [D191KA] (AJSS NEUTRAL SAFETY RELAY: DISCONNECTION)
— FAILURE CODE [D191KB] (AJSS NEUTRAL SAFETY RELAY: SHORT CIRCUIT)
— FAILURE CODE [D192KA] (ECSS SOLENOID: DISCONNECTION)
— FAILURE CODE [D192KB] (ECSS SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [D192KY] (ECSS SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [D198KA] (TRANSMISSION OIL PRESSURE BYPASS SOLENOID: DISCONNECTION)
— FAILURE CODE [D198KB] (TRANSMISSION OIL PRESSURE BYPASS SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [D198KY] (TRANSMISSION OIL PRESSURE BYPASS SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [D5ZHKA] (TERMINAL C SIGNAL: DISCONNECTION)
— FAILURE CODE [D5ZHKB] (TERMINAL C SIGNAL: SHORT CIRCUIT)
— FAILURE CODE [D5ZHKZ] (TERMINAL C SIGNAL: DISCONNECTION OR SHORT CIRCUIT)
— FAILURE CODE [D5ZHL6] (TERMINAL C SIGNAL: SIGNAL DOES NOT MATCH ENGINE RUNNING OR STOPPED STATE)
— FAILURE CODE [DA80L4] (AUTO GREASE CONTROLLER: ON/OFF SIGNALS DISAGREE)
— FAILURE CODE [DAF3KK] (MACHINE MONITOR: LOW SOURCE VOLTAGE (INPUT))
— FAILURE CODE [DAF5KP] (MACHINE MONITOR: LOW OUTPUT VOLTAGE)
— FAILURE CODE [DAFRKR] (CAN COMMUNICATION WITH MACHINE MONITOR: DEFECTIVE COMMUNICATION (ABNORMALITY IN TARGET COMPONENT SYSTEM))
— FAILURE CODE [DAQ0KK] (TRANSMISSION CONTROLLER: LOW SOURCE VOLTAGE)
— FAILURE CODE [DAQ0KT] (TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER)
— FAILURE CODE [DAQ2KK] (TRANSMISSION CONTROLLER LOAD POWER SUPPLY LINE: LOW SOURCE VOLTAGE (INPUT))
— FAILURE CODE [DAQ9KQ] (TRANSMISSION CONTROLLER MODEL SELECTION: DISAGREEMENT OF MODEL SELECTION SIGNALS)
— FAILURE CODE [DAQRKR] (CAN COMMUNICATION WITH TRANSMISSION CONTROLLER: DEFECTIVE COMMUNICATION (ABNORMALITY IN TARGET COMPONENT SYSTEM))
— FAILURE CODE [DAQRMA] (TRANSMISSION CONTROLLER CAN COMMUNICATION: MALFUNCTION)
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 5
— FAILURE CODE [DB2RKR] CAN COMMUNICATION FROM ENGINE CONTROLLER: DEFECTIVE COMMUNICATION (ABNORMALITY IN TARGET COMPONENT SYSTEM)
— FAILURE CODE [DB90KK] WORK EQUIPMENT CONTROLLER: LOW SOURCE VOLTAGE (INPUT)
— FAILURE CODE [DB90KT] (WORK EQUIPMENT CONTROLLER: ABNORMALITY IN CONTROLLER)
— FAILURE CODE [DB92KK] WORK EQUIPMENT CONTROLLER LOAD POWER SUPPLY LINE: LOW SOURCE VOLTAGE (INPUT)
— FAILURE CODE [DB95KX] (WORK EQUIPMENT CONTROLLER POWER SUPPLY OUTPUT: OUT OF INPUT SIGNAL RANGE)
— FAILURE CODE [DB99KQ] (WORK EQUIPMENT CONTROLLER MODEL SELECTION: DISAGREEMENT OF MODEL SELECTION SIGNALS)
— FAILURE CODE [DB9RKR] CAN COMMUNICATION WITH WORK EQUIPMENT CONTROLLER: DEFECTIVE COMMUNICATION (ABNORMALITY IN TARGET COMPONENT SYSTEM)
— FAILURE CODE [DB9RMA] (WORK EQUIPMENT CONTROLLER CAN COMMUNICATION: MALFUNCTION)
— FAILURE CODE [DB9RMC] (CAN COMMUNICATION WITH TRANSMISSION CONTROLLER: DEFECTIVE OPERATION)
— FAILURE CODE [DBB0KK] (OR VHMS_LED DISPLAY: “N9″→”01”) VHMS CONTROLLER: LOW SOURCE VOLTAGE (INPUT)
— FAILURE CODE [DBB0KQ] (OR VHMS_LED DISPLAY: “NF”→”11”) VHMS CONTROLLER: (DISAGREEMENT OF MODEL SELECTION SIGNALS)
— FAILURE CODE [DBB3KK] (OR VHMS_LED DISPLAY: “N9″→”05”) VHMS CONTROLLER BATTERY POWER SUPPLY: LOW SOURCE VOLTAGE (INPUT)
— FAILURE CODE [DBB5KP] (OR VHMS_LED DISPLAY: “N9″→”04”)(VHMS CONTROLLER 5 V POWER SUPPLY OUTPUT: LOW OUTPUT VOLTAGE)
— FAILURE CODE [DBB6KP] (OR VHMS_LED DISPLAY: “N9″→”02”)(VHMS CONTROLLER 24 V POWER SUPPLY OUTPUT: LOW OUTPUT VOLTAGE)
— FAILURE CODE [DBB7KP] (OR VHMS_LED DISPLAY: “N9″→”03”)(VHMS CONTROLLER 12 V POWER SUPPLY OUTPUT: LOW OUTPUT VOLTAGE)
— FAILURE CODE [DBBQKR] (OR VHMS_LED DISPLAY: “N8″→”02) VHMS CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (ABNORMALITY IN TARGET COMPONENT SYSTEM)
— FAILURE CODE [DD15LD] (■ SWITCH (PANEL SWITCH 1): SWITCH IS KEPT PRESSED FOR LONG TIME)
— FAILURE CODE [DD16LD] (◇ SWITCH (PANEL SWITCH 2): SWITCH IS KEPT PRESSED FOR LONG TIME)
— FAILURE CODE [DD17LD] (< SWITCH (PANEL SWITCH 3): SWITCH IS KEPT PRESSED FOR LONG TIME) -- FAILURE CODE [DD18LD] (> SWITCH (PANEL SWITCH 4): SWITCH IS KEPT PRESSED FOR LONG TIME)
— FAILURE CODE [DD1ALD] (REMOTE POSITIONER RAISE/LOWER SET SWITCH (RAISE): SWITCH IS KEPT PRESSED FOR LONG TIME)
— FAILURE CODE [DD1BLD] (REMOTE POSITIONER RAISE/LOWER SET SWITCH (LOWER): SWITCH IS KEPT PRESSED FOR LONG TIME)
— FAILURE CODE [DD1CLD] (LOAD METER SUBTOTAL SWITCH: SWITCH IS KEPT PRESSED FOR LONG TIME)
— FAILURE CODE [DD1FLD] (LOAD METER MODE SELECTOR SWITCH (A/B): SWITCH IS KEPT PRESSED FOR LONG TIME)
— FAILURE CODE [DD1GLD] (LOAD METER MODE SELECTOR SWITCH (+/-): SWITCH IS KEPT PRESSED FOR LONG TIME)
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 6
— FAILURE CODE [DD1HLD] (LOAD METER DISPLAY SELECTOR SWITCH: SWITCH IS KEPT PRESSED FOR LONG TIME)
— FAILURE CODE [DDA7L4] (RPM SET ON/OFF SWITCH: ON-OFF SIGNALS DISAGREE
— FAILURE CODE [DDA8KB] (RPM SET IDLE-UP/DOWN SELECTOR SWITCH (IDLE-UP): SHORT CIRCUIT)
— FAILURE CODE [DDA9KB] (RPM SET IDLE-UP/DOWN SELECTOR SWITCH (IDLE-DOWN): SHORT CIRCUIT)
— FAILURE CODE [DDB6L4] (TURN PARKING BRAKE SWITCH (NEUTRALIZER): ON/OFF SIGNALS DISAGREE)
— FAILURE CODE [DDD1LD] (REMOTE POSITIONER BUCKET ANGLE SET SWITCH: SWITCH IS KEPT PRESSED FOR LONG TIME)
— FAILURE CODE [DDDBKA] (TRACTION ADJUSTMENT DIAL: DISCONNECTION)
— FAILURE CODE [DDDBKB] (TRACTION ADJUSTMENT DIAL: SHORT CIRCUIT)
— FAILURE CODE [DDE5MA] (EMERGENCY STEERING DRIVE SWITCH: MALFUNCTION)
— FAILURE CODE [DDK4KA] (AJSS FNR SWITCH: DISCONNECTION)
— FAILURE CODE [DDK4KB] (AJSS FNR SWITCH: SHORT CIRCUIT)
— FAILURE CODE [DDK5L4] (AJSS SHIT-UP/DOWN SWITCH: ON/OFF SIGNALS DISAGREE)
— FAILURE CODE [DDK6KA] (FNR LEVER SWITCH: DISCONNECTION)
— FAILURE CODE [DDK6KB] (FNR LEVER SWITCH: SHORT CIRCUIT)
— FAILURE CODE [DDP5KA] (LOCK DETECTION PRESSURE SWITCH OF STEERING LOCK LEVER: DISCONNECTION)
— FAILURE CODE [DDT0L4] (SHIFT MODE SELECTOR SWITCH: ON/OFF SIGNALS DISAGREE)
— FAILURE CODE [DDW9LD] (KICK-DOWN SWITCH: SWITCH IS KEPT PRESSED FOR LONG TIME)
— FAILURE CODE [DDWLLD] (HOLD SWITCH: SWITCH IS KEPT PRESSED FOR LONG TIME)
— FAILURE CODE [DDY0LD] (LOAD METER CANCEL SWITCH: SWITCH IS KEPT PRESSED FOR LONG TIME)
— FAILURE CODE [DF10KA] (TRANSMISSION SHIFT LEVER SWITCH: DISCONNECTION)
— FAILURE CODE [DF10KB] (TRANSMISSION SHIFT LEVER SWITCH: SHORT CIRCUIT)
— FAILURE CODE [DGE5KX] (OR VHMS_LED DISPLAY: “N4″→”01”)(ATMOSPHERIC TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE)
— FAILURE CODE [DGF1KA] (TRANSMISSION OIL TEMPERATURE SENSOR: DISCONNECTION)
— FAILURE CODE [DGF1KB] (TRANSMISSION OIL TEMPERATURE SENSOR: SHORT CIRCUIT)
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 7
— FAILURE CODE [DGH2KX] (HYDRAULIC OIL TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE)
— FAILURE CODE [DGR2KA] (REAR BRAKE OIL TEMPERATURE SENSOR: DISCONNECTION)
— FAILURE CODE [DGR2KX] (REAR BRAKE OIL TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE)
— FAILURE CODE [DGT1KA] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: DISCONNECTION)
— FAILURE CODE [DGT1KB] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: SHORT CIRCUIT)
— FAILURE CODE [DGT1KX] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE)
— FAILURE CODE [DGT4KA] (OR VHMS_LED DISPLAY: “N3″→”12”)(EXHAUST GAS TEMPERATURE SENSOR (F): DISCONNECTION)
— FAILURE CODE [DGT4KB] (OR VHMS_LED DISPLAY: “N3″→”11”)(EXHAUST GAS TEMPERATURE SENSOR (F): SHORT CIRCUIT)
— FAILURE CODE [DGT5KA] (OR VHMS_LED DISPLAY: “N3″→”22”)(EXHAUST GAS TEMPERATURE SENSOR (R): DISCONNECTION)
— FAILURE CODE [DGT5KB] (OR VHMS_LED DISPLAY: “N3″→”21”)(EXHAUST GAS TEMPERATURE SENSOR (R): SHORT CIRCUIT)
— FAILURE CODE [DH21KA] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR: DISCONNECTION)
— FAILURE CODE [DH21KB] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT)
— FAILURE CODE [DHE5KB] (OR VHMS_LED DISPLAY: “N3″→”32”)(BLOW-BY PRESSURE SENSOR: SHORT CIRCUIT)
— FAILURE CODE [DHE5KY] (OR VHMS_LED DISPLAY: “N3″→”31”)(BLOW-BY PRESSURE SENSOR: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DHPCKX] (LIFT ARM CYLINDER BOTTOM PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE)
— FAILURE CODE [DHPDKX] (LIFT ARM CYLINDER HEAD PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE)
— FAILURE CODE [DHT2L6] (TRANSMISSION FILTER CLOGGING SENSOR: SIGNAL DISAGREES WITH OPERATING STATE OF ENGINE)
— FAILURE CODE [DHT8KX] (OR VHMS_LED DISPLAY: “N5″→”33”)(STEERING OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE)
— FAILURE CODE [DHTBKA] (MODULATION CLUTCH OIL PRESSURE SENSOR: DISCONNECTION)
— FAILURE CODE [DHTBKB] (MODULATION CLUTCH OIL PRESSURE SENSOR: SHORT CIRCUIT)
— FAILURE CODE [DHU2KX] (OR VHMS_LED DISPLAY: “N7″→”11”)(FRONT BRAKE OIL PRESSURE SENSOR (F): OUT OF INPUT SIGNAL RANGE)
— FAILURE CODE [DHU3KX] (OR VHMS_LED DISPLAY: “N7″→”12”)(REAR BRAKE OIL PRESSURE SENSOR (R): OUT OF INPUT SIGNAL RANGE)
— FAILURE CODE [DK30KA] (AJSS LEVER ANGLE SENSOR: DISCONNECTION)
— FAILURE CODE [DK30KY] (AJSS LEVER ANGLE SENSOR: SHORT CIRCUIT WITH POWER SUPPLY LINE)
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 8
— FAILURE CODE [DK59KA] (LIFT ARM EPC LEVER POTENTIOMETER (MAIN): DISCONNECTION)
— FAILURE CODE [DK59KY] (LIFT ARM EPC LEVER POTENTIOMETER (MAIN): SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DK59L8] (LIFT ARM EPC LEVER POTENTIOMETER (MAIN): ANALOG SIGNALS DISAGREE)
— FAILURE CODE [DK5AKA] (LIFT ARM EPC LEVER POTENTIOMETER (SUB): DISCONNECTION)
— FAILURE CODE [DK5AKY] (LIFT ARM EPC LEVER POTENTIOMETER (SUB): SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DK5BKA] (BUCKET EPC LEVER POTENTIOMETER (MAIN): DISCONNECTION)
— FAILURE CODE [DK5BKY] (BUCKET EPC LEVER POTENTIOMETER (MAIN): SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DK5BL8] (BUCKET EPC LEVER POTENTIOMETER (MAIN): ANALOG SIGNALS DISAGREE)
— FAILURE CODE [DK5CKA] (BUCKET EPC LEVER POTENTIOMETER (SUB): DISCONNECTION)
— FAILURE CODE [DK5CKY] (BUCKET EPC LEVER POTENTIOMETER (SUB): SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DK5DKA] (3-SPOOL VALVE (ATTACHMENT) EPC LEVER POTENTIOMETER (MAIN): DISCONNECTION)
— FAILURE CODE [DK5DKY] (3-SPOOL VALVE (ATTACHMENT) EPC LEVER POTENTIOMETER (MAIN): SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DK5DL8] (3-SPOOL VALVE (ATTACHMENT) EPC LEVER POTENTIOMETER (MAIN): ANALOG SIGNALS DISAGREE)
— FAILURE CODE [DK5EKA] (3-SPOOL VALVE (ATTACHMENT) EPC LEVER POTENTIOMETER (SUB): DISCONNECTION)
— FAILURE CODE [DK5EKY] (3-SPOOL VALVE EPC LEVER POTENTIOMETER (SUB): SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DKA0KA] (LIFT ARM ANGLE SENSOR: DISCONNECTION)
— FAILURE CODE [DKA0KX] (LIFT ARM ANGLE SENSOR: OUT OF INPUT SIGNAL RANGE)
— FAILURE CODE [DKA0KY] (LIFT ARM ANGLE SENSOR: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DKA0L0] (LIFT ARM ANGLE SENSOR: IMPROPER POSITION)
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 9
— FAILURE CODE [DKD0KA] (FRAME ANGLE SENSOR: DISCONNECTION)
— FAILURE CODE [DKD0KY] (FRAME ANGLE SENSOR: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DKD0KZ] (AJSS LEVER AND FRAME ANGLE SENSOR: DISCONNECTION OR SHORT CIRCUIT)
— FAILURE CODE [DLFAKA] (MODULATION CLUTCH OUTPUT SHAFT SPEED SENSOR: DISCONNECTION)
— FAILURE CODE [DLFALC] (MODULATION CLUTCH OUTPUT SHAFT SPEED SENSOR: SPEED SIGNALS DISAGREE)
— FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR (2): DISCONNECTION)
— FAILURE CODE [DLT3LC] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR (2): SPEED SIGNALS DISAGREE)
— FAILURE CODE [DLT4KB] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR (1): SHORT CIRCUIT)
— FAILURE CODE [DLT4KX] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR (1): OUT OF INPUT SIGNAL RANGE)
— FAILURE CODE [DUM1KB] (REMOTE POSITIONER RAISE INDICATOR LAMP: SHORT CIRCUIT)
— FAILURE CODE [DUM2KB] (REMOTE POSITIONER LOWER INDICATOR LAMP: SHORT CIRCUIT)
— FAILURE CODE [DV00KB] (ALARM BUZZER: SHORT CIRCUIT)
— FAILURE CODE [DW4PKA] (LIFT ARM RAISE EPC SOLENOID: DISCONNECTION)
— FAILURE CODE [DW4PKB] (LIFT ARM RAISE EPC SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DW4PKY] (LIFT ARM RAISE EPC SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DW4QKA] (LIFT ARM LOWER EPC SOLENOID: DISCONNECTION)
— FAILURE CODE [DW4QKB] (LIFT ARM LOWER EPC SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DW4QKY] (LIFT ARM LOWER EPC SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DW4RKA] (BUCKET TILT EPC SOLENOID: DISCONNECTION)
— FAILURE CODE [DW4RKB] (BUCKET TILT EPC SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DW4RKY] (BUCKET TILT EPC SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DW4SKA] (BUCKET DUMP EPC SOLENOID: DISCONNECTION)
— FAILURE CODE [DW4SKB] (BUCKET DUMP EPC SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DW4SKY] (BUCKET DUMP EPC SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DW7BKA] (FAN REVERSE SOLENOID: DISCONNECTION)
— FAILURE CODE [DW7BKB] (FAN REVERSE SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DW7BKY] (FAN REVERSE SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DW7DKA] (HYDRAULIC DRIVE FAN NEUTRAL SOLENOID: DISCONNECTION)
— FAILURE CODE [DW7DKB] (HYDRAULIC DRIVE FAN NEUTRAL SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DW7DKY] (HYDRAULIC DRIVE FAN NEUTRAL SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 10
— FAILURE CODE [DWM1KA] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID: DISCONNECTION)
— FAILURE CODE [DWM1KB] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DWM1KY] (WORK EQUIPMENT NEUTRAL LOCK EPC SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DWN6KA] (LIFT ARM RAISE MAGNET DETENT SOLENOID: DISCONNECTION)
— FAILURE CODE [DWN6KB] (LIFT ARM RAISE MAGNET DETENT SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DWN6KY] (LIFT ARM RAISE MAGNET DETENT SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DWN7KA] (LIFT ARM FLOAT MAGNET DETENT SOLENOID: DISCONNECTION)
— FAILURE CODE [DWN7KB] (LIFT ARM FLOAT MAGNET DETENT SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DWN7KY] (LIFT ARM FLOAT MAGNET DETENT SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DWN8KA] (BUCKET TILT MAGNET DETENT SOLENOID: DISCONNECTION)
— FAILURE CODE [DWN8KB] (BUCKET TILT MAGNET DETENT SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DWN8KY] (BUCKET TILT MAGNET DETENT SOLENOID: SHORTED WITH THE POWER SOURCE)
— FAILURE CODE [DWNFKA] (MODULATION CLUTCH CUT-OFF RELEASE SOLENOID: DISCONNECTION)
— FAILURE CODE [DWNFKB] (MODULATION CLUTCH CUT-OFF RELEASE SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DWNFKY] (MODULATION CLUTCH CUT-OFF RELEASE SOLENOID: SHORT CIRCUIT WITH POWER SOURCE LINE)
— FAILURE CODE [DX16KA] (FAN PUMP EPC SOLENOID: DISCONNECTION)
— FAILURE CODE [DX16KB] (FAN PUMP EPC SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DX16KY] (FAN PUMP EPC SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DXA1KA] (PUMP PC-EPC SOLENOID: DISCONNECTION)
— FAILURE CODE [DXA1KB] (PUMP PC-EPC SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DXF0KA] (AJSS EPC SOLENOID: DISCONNECTION)
— FAILURE CODE [DXF0KB] (AJSS EPC SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DXH1KA] (LOCKUP ECMV SOLENOID: DISCONNECTION)
— FAILURE CODE [DXH1KB] (LOCKUP ECMV SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DXH1KY] (LOCKUP ECMV SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DXH4KA] (1ST CLUTCH ECMV SOLENOID: DISCONNECTION)
— FAILURE CODE [DXH4KB] (1ST CLUTCH ECMV SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DXH4KY] (1ST CLUTCH ECMV SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 11
— FAILURE CODE [DXH5KA] (2ND CLUTCH ECMV SOLENOID: DISCONNECTION)
— FAILURE CODE [DXH5KB] (2ND CLUTCH ECMV SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DXH5KY] (2ND CLUTCH ECMV SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DXH6KA] (3RD CLUTCH ECMV SOLENOID: DISCONNECTION)
— FAILURE CODE [DXH6KB] (3RD CLUTCH ECMV SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DXH6KY] (3RD CLUTCH ECMV SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DXH7KA] (R CLUTCH ECMV SOLENOID: DISCONNECTION)
— FAILURE CODE [DXH7KB] (R CLUTCH ECMV SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DXH7KY] (R CLUTCH ECMV SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DXH8KA] (F CLUTCH ECMV SOLENOID: DISCONNECTION)
— FAILURE CODE [DXH8KB] (F CLUTCH ECMV SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DXH8KY] (F CLUTCH ECMV SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DXHHKA] (4TH CLUTCH ECMV SOLENOID: DISCONNECTION)
— FAILURE CODE [DXHHKB] (4TH CLUTCH ECMV SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DXHHKY] (4TH CLUTCH ECMV SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DXHJKA] (3-SPOOL VALVE EXTRACT EPC SOLENOID: DISCONNECTION)
— FAILURE CODE [DXHJKB] (3-SPOOL VALVE EXTRACT EPC SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DXHJKY] (3-SPOOL VALVE EXTRACT EPC SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DXHKKA] (3-SPOOL VALVE RETRACT EPC SOLENOID: DISCONNECTION)
— FAILURE CODE [DXHKKB] (3-SPOOL VALVE RETRACT EPC SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DXHKKY] (3-SPOOL VALVE RETRACT EPC SOLENOID: SHORT CIRCUIT WITH POWER SUPPLY LINE)
— FAILURE CODE [DXHPKA] (MODULATION CLUTCH SOLENOID: DISCONNECTION)
— FAILURE CODE [DXHPKB] (MODULATION CLUTCH SOLENOID: SHORT CIRCUIT)
— FAILURE CODE [DXHPKY] (MODULATION CLUTCH SOLENOID: SHORT CIRCUIT WITH POWER SOURCE LINE)
— FAILURE CODE [DXHPMA] (MODULATION CLUTCH SOLENOID: MALFUNCTION)
— FAILURE CODE [F@BBZL] (OR VHMS_LED DISPLAY: “N3″→”38”)(BLOW-BY PRESSURE: HIGH ERROR)
— FAILURE CODE [F@BYNR] (OR VHMS_LED DISPLAY: “N3″→”62”)(EXHAUST GAS TEMPERATURE (F): ABNORMAL HEAT)
— FAILURE CODE [F@BYNS] (OR VHMS_LED DISPLAY: “N3″→”61”)(EXHAUST GAS TEMPERATURE (F): OVERHEAT)
— FAILURE CODE [F@BZNR] (OR VHMS_LED DISPLAY: “N3″→”72”)(EXHAUST GAS TEMPERATURE (R): ABNORMAL HEAT)
— FAILURE CODE [F@BZNS] (OR VHMS_LED DISPLAY: “N3″→”71”)(EXHAUST GAS TEMPERATURE (R): OVERHEAT)
– TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
— BEFORE CARRYING OUT TROUBLESHOOTING OF 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 STEP LAMP DOES NOT LIGHT UP OR GO OFF
— E-7 TURN SIGNAL LAMP AND HAZARD LAMP DO NOT LIGHT UP OR GO OFF
— E-8 BRAKE LAMP DOES NOT LIGHT OR IT KEEPS LIGHTING UP.
— E-9 BACKUP LAMP DOES NOT LIGHT OR IT KEEPS LIGHTING UP.
— E-10 BACKUP BUZZER DOES NOT SOUND OR IT KEEPS SOUNDING.
— E-11 HORN DOES NOT SOUND OR IT KEEPS SOUNDING.
— E-12 ALARM BUZZER DOES NOT SOUND OR IT KEEPS SOUNDING
— E-13 AIR CONDITIONER DOES NOT OPERATE OR STOP
— E-14 ELECTRIC PRIMING PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY
– TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
— METHOD OF USING TROUBLESHOOTING CHART
— TABLE OF FAILURE MODES AND CAUSES
— H-1 MACHINE DOES NOT START
— H-2 TORQUE CONVERTER LOCKUP IS NOT SWITCHED (ENGINE STALLS)
— H-3 TORQUE CONVERTER LOCKUP IS NOT TURNED ON
— H-4 TRAVEL SPEED IS SLOW, THRUSTING FORCE IS WEAK, UPHILL TRAVELING POWER IS WEAK, AND GEAR IS NOT SHIFTED
— H-5 SHOCKS ARE LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR
— H-6 TIME LAG IS LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR
— H-7 TORQUE CONVERTER OIL TEMPERATURE IS HIGH
— H-8 STEERING DOES NOT TURN [MACHINE WITH STEERING WHEEL]
— H-9 STEERING DOES NOT TURN [MACHINE WITH AJSS]
— H-10 TURNING, RESPONSE OF STEERING IS POOR [MACHINE WITH STEERING WHEEL]
— H-11 TURNING, RESPONSE OF AJSS IS POOR [MACHINE WITH AJSS]
— H-12 STEERING IS HEAVY [MACHINE WITH STEERING WHEEL]
— H-13 WHEN MACHINE TURNS, IT SHAKES OR MAKES LARGE SHOCKS [MACHINE WITH STEERING WHEEL]
— H-14 WHEN MACHINE TURNS, IT SHAKES OR MAKES LARGE SHOCKS [MACHINE WITH AJSS]
— 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 (INCLUDING EMERGENCY RELEASE SYSTEM)
— H-19 LIFT ARM DOES NOT RISE
— H-20 LIFT ARM SPEED IS LOW OR RISING FORCE OF LIFT ARM IS INSUFFICIENT
— H-21 WHEN RISING, LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT
— H-22 LIFT ARM CYLINDER CANNOT HOLD DOWN BUCKET (BUCKET FLOATS)
— H-23 HYDRAULIC DRIFTS OF LIFT ARM OCCUR OFTEN
— 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 COMES TO OPERATE SLOWLY IN THE MIDST OF TILTING-BACK
— H-28 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET
— H-29 HYDRAULIC DRIFTS OF BUCKET OCCUR OFTEN
— H-30 BUCKET WOBBLES DURING TRAVEL WITH CARGO (WORK EQUIPMENT VALVE IS SET TO “HOLD”)
— H-31 DURING OPERATION OF MACHINE, ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS
— H-32 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS AND STOPS
— H-33 WHEN WORK EQUIPMENT CIRCUIT IS RELIEVED SINGLY, OTHER WORK EQUIPMENT MOVES
— H-34 ECSS DOES NOT OPERATE, AND PITCHING BOUNCING OCCURS
— H-35 FAN SPEED IS ABNORMAL (FAN SOUND AND VIBRATION ARE ABNORMALLY LARGE OR ENGINE OVERHEATS)
– TROUBLESHOOTING OF ENGINE (S-MODE)
— METHOD OF USING TROUBLESHOOTING CHART
— S-1 ENGINE DOES NOT START EASILY.
— S-2 ENGINE DOES NOT START
— S-3 ENGINE DOES NOT PICK UP SMOOTHLY
— S-4 ENGINE STOPS DURING OPERATION
— S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING OCCURS)
— S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
— S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
— S-8 OIL IS CONSUMED MUCH (OR EXHAUST GAS COLOR IS BLUE)
— S-9 ENGINE OIL BECOMES CONTAMINATED QUICKLY
— S-10 FUEL CONSUMPTION IS EXCESSIVE
— S-11 COOLANT CONTAINS OIL (BLOWS BACK OR REDUCES)
— S-12 OIL PRESSURE DROPS
— S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)
— S-14 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)
— S-15 ABNORMAL NOISE IS MADE
— S-16 VIBRATION IS EXCESSIVE
— S-17 AIR CANNOT BE BLED FROM FUEL CIRCUIT
50 DISASSEMBLY AND ASSEMBLY
– GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY
— HOW TO READ THIS MANUAL
— COATING MATERIALS LIST
— SPECIAL TOOL LIST
— SKETCHES OF SPECIAL TOOLS
– ENGINE AND COOLING SYSTEM, PART 1
— REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
— REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
— REMOVAL AND INSTALLATION OF AIR AFTERCOOLER
— REMOVAL AND INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY
— REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF DAMPER ASSEMBLY
— REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
— REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY
— REMOVAL AND INSTALLATION OF BULKHEAD ASSEMBLY
– ENGINE AND COOLING SYSTEM, PART 2
— REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY
— REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
— REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
— REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
— REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
– POWER TRAIN, PART 1
— REMOVAL AND INSTALLATION OF PARKING BRAKE ASSEMBLY
— REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY
– POWER TRAIN, PART 2
— DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF TRANSFER ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY
– POWER TRAIN, PART 3
— REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY
— REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY
— REMOVAL AND INSTALLATION OF CENTER SUPPORT ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF CENTER SUPPORT ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
– POWER TRAIN, PART 4
— REMOVAL AND INSTALLATION OF FINAL DRIVE CARRIER ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE CARRIER ASSEMBLY
— REMOVAL AND INSTALLATION OF FRONT FINAL DRIVE BRAKE ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
– BRAKE SYSTEM
— DISASSEMBLY AND ASSEMBLY OF BRAKE ASSEMBLY
— REMOVAL AND INSTALLATION OF BRAKE VALVE ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF ACCUMULATOR AND CHARGE VALVE ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF SLACK ADJUSTOR ASSEMBLY
– UNDERCARRIAGE AND FRAME
— REMOVAL AND INSTALLATION OF CENTER HINGE PIN
— REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY
– HYDRAULIC SYSTEM
— REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY
— REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY
— REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY
— REMOVAL AND INSTALLATION OF STEERING VALVE ASSEMBLY
— REMOVAL AND INSTALLATION OF ECSS ACCUMULATOR ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
– WORK EQUIPMENT
— REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY
– CAB AND ITS ATTACHMENTS
— REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY
— REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)
— REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY
– ELECTRICAL SYSTEM
— REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY
— REMOVAL AND INSTALLATION OF TRANSMISSION CONTROLLER ASSEMBLY
— REMOVAL AND INSTALLATION OF LOADER CONTROLLER ASSEMBLY
— REMOVAL AND INSTALLATION OF VHMS CONTROLLER ASSEMBLY
— REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY
— REMOVAL AND INSTALLATION OF PRINTER ASSEMBLY
— REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY
90 DIAGRAMS AND DRAWINGS
– HYDRAULIC DIAGRAMS AND DRAWINGS
— POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
— BRAKE HYDRAULIC CIRCUIT DIAGRAM
— WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
– Electrical diagrams and drawings
— Air conditioner electrical circuit diagram
— Steering wheel specification

— Electrical circuit diagram (1/10)
— Electrical circuit diagram (2/10)
— Electrical circuit diagram (3/10)
— Electrical circuit diagram (4/10)
— Electrical circuit diagram (5/10)
— Electrical circuit diagram (6/10)
— Electrical circuit diagram (7/10)
— Electrical circuit diagram (8/10)
— Electrical circuit diagram (9/10)
— Electrical circuit diagram (10/10)
— AJSS (Advanced Joystick Steering System) specification
— Electrical circuit diagram (1/10)
— Electrical circuit diagram (2/10)
— Electrical circuit diagram (3/10)
— Electrical circuit diagram (4/10)
— Electrical circuit diagram (5/10)
— Electrical circuit diagram (6/10)
— Electrical circuit diagram (7/10)
— Electrical circuit diagram (8/10)
— Electrical circuit diagram (9/10)
— Electrical circuit diagram (10/10)
— Connector arrangement diagram