Komatsu WA800-3E0 70001 & Up, WA900-3E0 60001 & Up SEN02034-01 (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 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
— GENERAL ASSEMBLY DRAWING
— SPECIFICATIONS
— WEIGHT TABLE
— TABLE OF FUEL, COOLANT AND LUBRICANTS
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
– ENGINE AND COOLING SYSTEM
— ENGINE MOUNT
— TRANSMISSION MOUNT
— DAMPER
— RADIATOR, OIL COOLER, AFTERCOOLER
— FUEL SYSTEM
– POWER TRAIN, PART 1
— POWER TRAIN
— POWER TRAIN SYSTEM
— TORQUE CONVERTER
— TORQUE CONVERTER REGULATOR VALVE
— TRANSMISSION
— TRANSFER
— TRANSMISSION CONTROL VALVE
– POWER TRAIN, PART 2
— TORQUE CONVERTER OIL COOLER
— DRIVE SHAFT
— CENTER SUPPORT
— AXLE
— DIFFERENTIAL
— FINAL DRIVE
– STEERING SYSTEM
— STEERING PIPING
— AJSS LEVER LINKAGE
— EPC VALVE
— ROTARY VALVE
— STEERING CONTROL VALVE
— STEERING PUMP
— STEERING CYLINDER
— SLOW RETURN VALVE
— EMERGENCY STEERING PIPING
— DIVERTER VALVE
— EMERGENCY STEERING PUMP
– BRAKE SYSTEM
— BRAKE PIPING
— BRAKE
— BRAKE VALVE
— ACCUMULATOR CHARGE VALVE
— PPC RELIEF VALVE
— ACCUMULATOR (FOR BRAKE)
— SLACK ADJUSTER
— PARKING BRAKE
— PARKING BRAKE CALIPER
— SPRING CYLINDER
— PARKING BRAKE SOLENOID
– UNDERCARRIAGE AND FRAME
— AXLE MOUNT
— CENTER HINGE PIN
— TIRE AND WHEEL
— JACK UP POINT
– HYDRAULIC SYSTEM, PART 1
— HYDRAULIC PIPING
— WORK EQUIPMENT LEVER LINKAGE
— HYDRAULIC TANK
— TORQUE CONBVERTER CHARGING, PPC AND BRAKE PUMP
– HYDRAULIC SYSTEM, PART 2
— MAIN CONTROL VALVE
— ACCUMULATOR (FOR PPC VALVE)
— MAIN PISTON PUMP
— MAIN PISTON PUMP CUT-OFF SOLENOID VALVE
— PPC VALVE
— PPC RELIEF VALVE
— SWITCH PUMP
— CONTROL PUMP
– WORK EQUIPMENT
— WORK EQUIPMENT LINKAGE
— BUCKET POSITIONER AND LIFT ARM KICK-OUT
— REMOTE LIFT ARM POSITIONER
— AUTO GREASING SYSTEM
— HYDRAULIC CYLINDER
– CAB AND ITS ATTACHMENTS
— ROPS CAB
— AIR CONDITIONER
– ELECTRICAL SYSTEM, PART 1
— MACHINE MONITOR SYSTEM
— MAIN MONITOR
— MAINTENANCE MONITOR
– ELECTRICAL SYSTEM, PART 2
— WORK EQUIPMENT CONTROL SYSTEM
— REMOTE POSITION, JOYSTICK STEERING CONTROLLER
— ACTIVE POWER MAXIMIZING ELECTRICAL CIRCUIT
— AUTOMATIC TRANSMISSION SYSTEM (ATM)
– ELECTRICAL SYSTEM, PART 3
— ENGINE STARTING/STOPPING CIRCUIT
— PARKING BRAKE CIRCUIT
— PREHEATING CIRCUIT
— SENSOR
— KICK-DOWN, HOLD SWITCH
20 STANDARD VALUE TABLE
– STANDARD SERVICE VALUE TABLE
— STANDARD VALUE TABLE FOR ENGINE
— STANDARD VALUE TABLE FOR CHASSIS
— STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
30 TESTING AND ADJUSTING
– TESTING AND ADJUSTING, PART 1
— TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
— MEASURING ENGINE SPEED
— MEASURING INTAKE AIR (BOOST) PRESSURE
— MEASURING EXHAUST GAS COLOR
— MEASURING EXHAUST TEMPERATURE
— ADJUSTING VALVE CLEARANCE
— MEASURING COMPRESSION PRESSURE
— MEASURING BLOW-BY PRESSURE
— MEASURING ENGINE OIL PRESSURE
— HANDLING FUEL SYSTEM EQUIPMENT
— RELEASING RESIDUAL PRESSURE IN FUEL SYSTEM
— TESTING FUEL PRESSURE
— MEASURING FUEL 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
— ADJUSTING SPEED SENSOR
— TESTING AND ADJUSTING ALTERNATOR BELT TENSION
— TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR
— TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE
— PROCEDURE FOR OPERATING EMERGENCY STEERING SPOOL WHEN TRANSMISSION VALVE FAILS
– 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)
— MEASURING STEERING OIL PRESSURE
— TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE
— BLEEDING AIR FROM STEERING CIRCUIT
— MEASURING BRAKE PEDAL
— MEASURING BRAKE PERFORMANCE
— TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
— MEASURING WHEEL BRAKE OIL PRESSURE REDUCTION
— 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 SOLENOID OIL PRESSURE
— TESTING AND ADJUSTING WEAR OF PARKING BRAKE PAD
— TESTING AND ADJUSTING PPC OIL PRESSURE
— ADJUSTING PPC VALVE LINKAGE
— TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
— BLEEDING AIR FROM PISTON PUMP
— BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT
— ADJUSTING WORK EQUIPMENT LEVER LINKAGE
— RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
— TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH
— TESTING AND ADJUSTING LIFT ARM PROXIMITY SWITCH
— TESTING AND ADJUSTING ACTIVE WORKING PROXIMITY SWITCH
— CHECKING PROXIMITY SWITCH OPERATION PILOT LAMP
— TESTING AND ADJUSTING LIFT ARM POSITION DETECTION LEVER
— ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR
– TESTING AND ADJUSTING, PART 3
— SPECIAL FUNCTION OF ENGINE SERVICE MONITOR
— VHMS CONTROLLER INITIAL SETTING PROCEDURE
— PRECAUTIONS FOR REPLACING VHMS CONTROLLER
— PM-CLICK INSPECTION TABLE
40 TROUBLESHOOTING
– FAILURE CODE TABLE AND FUSE LOCATIONS
— FAILURE CODE TABLE
— METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE ON MACHINE MONITOR
— TRANSMISSION & AJSS CONTROLLER LED DISPLAY
— TRANSMISSION CONTROL SYSTEM
— AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM
— LOCATION OF FUSE
– GENERAL INFORMATION ON TROUBLESHOOTING
— POINTS TO REMEMBER WHEN TROUBLESHOOTING
— SEQUENCE OF EVENTS IN TROUBLESHOOTING
— TESTING BEFORE TROUBLESHOOTING
— CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
— CONTENTS OF TROUBLESHOOTING TABLE
— WIRING TABLE FOR CONNECTOR PIN NUMBERS
— T-ADAPTER BOX AND T-ADAPTER TABLE
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 1
— FAILURE CODE [15B0NX] (TRANSMISSION OIL FILTER: CLOGGING)
— FAILURE CODE [AA1ANX] (AIR CLEANER L.H: CLOGGED)
— FAILURE CODE [AA1BNX] (AIR CLEANER R.H: CLOGGED)
— FAILURE CODE [AB00L4] (ALTERNATOR: FAILURE ON BATTERY CHARGE CIRCUIT (R TERMINAL SIGNAL IS PRESENT AND ENGINE IS STOPPED)
— FAILURE CODE [AB00L6] (ALTERNATOR: FAILURE ON BATTERY CHARGE CIRCUIT (R TERMINAL SIGNAL IS PRESENT AND ENGINE IS STOPPED)
— FAILURE CODE [AB00MA] (ALTERNATOR: FAILURE ON BATTERY CHARGE CIRCUIT (ABSENCE OF R TERMINAL SIGNAL AND DETECTION ERROR)
— FAILURE CODE [AB00MB] (ALTERNATOR: FAILURE ON BATTERY CHARGE CIRCUIT (ABSENCE OF R TERMINAL SIGNAL AND DETECTION ERROR)
— FAILURE CODE [AB00MC] (ALTERNATOR: FAILURE ON BATTERY CHARGE CIRCUIT (ABSENCE OF R TERMINAL SIGNAL AND DETECTION ERROR)
— FAILURE CODE [B@BAZK] (ENGINE OIL: OIL LEVEL LOW)
— FAILURE CODE [B@BBZG] (ENGINE OIL: LOW OIL PRESSURE)
— FAILURE CODE [B@BCZK] AND [B@BCZK] (RADIATOR COOLANT: LOW COOLANT LEVEL)
— FAILURE CODE [B@BDNS] (ENGINE: OVERHEATING)
— FAILURE CODE [B@C6NS] (FRONT BRAKE OIL TEMPERATURE: OVERHEATING)
— FAILURE CODE [B@CENS] (TORQUE CONVERTER OIL TEMPERATURE OVERHEATING)
— FAILURE CODE [B@JFZG] (BRAKE OIL: LOW OIL PRESSURE)
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 2
— FAILURE CODE [CA111] ENGINE CONTROLLER (LEFT BANK): INTERNAL ABNORMALITY
— FAILURE CODE [CB111] ENGINE CONTROLLER (RIGHT BANK): INTERNAL ABNORMALITY
— FAILURE CODE [CA115] ABNORMAL ENGINE NE AND BKUP SPEED SENSORS (AT LEFT BANK): ABNORMAL SPEED SENSOR SIGNAL
— FAILURE CODE [CB115] ABNORMAL ENGINE NE AND BKUP SPEED SENSORS (AT RIGHT BANK): ABNORMAL SPEED SENSOR SIGNAL
— FAILURE CODE [CA122] CHARGE PRESSURE SENSOR TOO HIGH (AT LEFT BANK ONLY): EXCESSIVELY HIGH VOLTAGE DETECTED
— FAILURE CODE [CA123] CHARGE PRESSURE SENSOR TOO LOW (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTED
— FAILURE CODE [CA131] THROTTLE SENSOR ABNORMALLY HIGH LEVEL (ONLY LEFT BANK): HIGH VOLTAGE DETECTION
— FAILURE CODE [CA132] THROTTLE SENSOR TOO LOW (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTED
— FAILURE CODE [CA135] OIL PRESSURE SENSOR TOO HIGH (AT LEFT BANK ONLY): EXCESSIVELY HIGH VOLTAGE DETECTED
— FAILURE CODE [CA141] OIL PRESSURE SENSOR TOO LOW (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTED
— FAILURE CODE [CA144] COOLANT TEMPERATURE SENSOR TOO HIGH: EXCESSIVELY HIGH VOLTAGE DETECTED
— FAILURE CODE [CA145] COOLANT TEMPERATURE SENSOR TOO LOW (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTED
— FAILURE CODE [CA153] CHARGE TEMPERATURE SENSOR TOO HIGH (AT LEFT BANK ONLY): EXCESSIVELY HIGH VOLTAGE DETECTED
— FAILURE CODE [CA154] CHARGE TEMPERATURE SENSOR TOO LOW (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTED
— FAILURE CODE [CA187] SENSOR POWER SUPPLY (2) ABNORMALLY LOW LEVEL (LEFT BANK): LOW VOLTAGE DETECTION
— FAILURE CODE [CB187] SENSOR POWER SUPPLY (2) ABNORMALLY LOW LEVEL (RIGHT BANK): LOW VOLTAGE DETECTION
— FAILURE CODE [CA212] ENGINE OIL TEMPERATURE SENSOR ABNORMALLY HIGH LEVEL (ONLY LEFT BANK): HIGH VOLTAGE DETECTION
— FAILURE CODE [CA213] ENGINE OIL TEMPERATURE SENSOR ABNORMALLY LOW LEVEL (ONLY LEFT BANK): LOW VOLTAGE DETECTION
— FAILURE CODE [CA221] ATMOSPHERIC PRESSURE SENSOR TOO HIGH (AT LEFT BANK ONLY): EXCESSIVELY HIGH VOLTAGE DETECTED
— FAILURE CODE [CA222] ATMOSPHERIC PRESSURE SENSOR TOO LOW (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTED
— FAILURE CODE [CA227] SENSOR POWER SOURCE (2) TOO HIGH (AT LEFT BANK): EXCESSIVELY HIGH VOLTAGE DETECTED
— FAILURE CODE [CB227] SENSOR POWER SUPPLY (2) ABNORMALLY HIGH LEVEL (RIGHT BANK): HIGH VOLTAGE DETECTION
— FAILURE CODE [CA234] ENGINE OVER SPEED (AT LEFT BANK ONLY): EXCESSIVELY HIGH SPEED
— FAILURE CODE [CA238] ABNORMAL POWER SOURCE FOR NE SPEED SENSOR (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTED
— FAILURE CODE [CB238] ABNORMAL POWER SOURCE FOR NE SPEED SENSOR (AT RIGHT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTED
— FAILURE CODE [CA263] FUEL TEMPERATURE SENSOR TOO HIGH (AT LEFT BANK): EXCESSIVELY HIGH VOLTAGE DETECTED
— FAILURE CODE [CB263] FUEL TEMPERATURE SENSOR TOO HIGH (AT RIGHT BANK): EXCESSIVELY HIGH VOLTAGE DETECTD
— FAILURE CODE [CA265] FUEL TEMPERATURE SENSOR ABNORMALLY LOW LEVEL (LEFT BANK): LOW VOLTAGE DETECTION
— FAILURE CODE [CB265] FUEL TEMPERATURE SENSOR ABNORMALLY LOW LEVEL (RIGHT BANK): LOW VOLTAGE DETECTION
— FAILURE CODE [CA271] PCV1 SHORT CIRCUIT (LEFT BANK): SHORT CIRCUIT
— FAILURE CODE [CB271] PCV1 SHORT CIRCUIT (RIGHT BANK): SHORT CIRCUIT
— FAILURE CODE [CA272] PCV1 DISCONNECTION (LEFT BANK): DISCONNECTION
— FAILURE CODE [CB272] PCV1 DISCONNECTION (RIGHT BANK): DISCONNECTION
— FAILURE CODE [CA273] PCV2 SHORT CIRCUIT (LEFT BANK): SHORT CIRCUIT
— FAILURE CODE [CB273] PCV2 SHORT CIRCUIT (RIGHT BANK): SHORT CIRCUIT
— FAILURE CODE [CA274] PCV2 DISCONNECTION (LEFT BANK): DISCONNECTION
— FAILURE CODE [CB274] PCV2 DISCONNECTION (RIGHT BANK): DISCONNECTION
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 3
— FAILURE CODE [CA322] INJECTOR NO. 1 (L/B NO.1) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK): DISCONNECTION, SHORT CIRCUIT
— FAILURE CODE [CA323] INJECTOR NO. 5 (L/B NO.5) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK): DISCONNECTION, SHORT CIRCUIT
— FAILURE CODE [CA324] INJECTOR NO. 3 (L/B NO.3) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK): DISCONNECTION, SHORT CIRCUIT
— FAILURE CODE [CA325] INJECTOR NO. 6 (L/B NO.6) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK): DISCONNECTION, SHORT CIRCUIT
— FAILURE CODE [CA331] INJECTOR NO. 2 (L/B NO.2) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK): DISCONNECTION, SHORT CIRCUIT
— FAILURE CODE [CA332] INJECTOR NO. 4 (L/B NO.4) SYSTEM DISCONNECTION OR SHORT CIRCUIT (AT LEFT BANK): DISCONNECTION, SHORT CIRCUIT
— FAILURE CODE [CA342] ENGINE CONTROLLER DATA MISMATCH (LEFT BANK): MISMATCH
— FAILURE CODE [CB342] ENGINE CONTROLLER DATA MISMATCH (RIGHT BANK): MISMATCH
— FAILURE CODE [CA351] ABNORMAL INJECTOR DRIVE CIRCUIT (AT LEFT BANK): ABNORMAL CIRCUIT
— FAILURE CODE [CB351] INJECTOR DRIVE CIRCUIT ABNORMALITY (RIGHT BANK): CIRCUIT ABNORMALITY
— FAILURE CODE [CA352] SENSOR POWER SUPPLY (1) ABNORMALLY LOW LEVEL (LEFT BANK): LOW VOLTAGE DETECTION
— FAILURE CODE [CB352] SENSOR POWER SUPPLY (1) ABNORMALLY LOW LEVEL (RIGHT BANK): LOW VOLTAGE DETECTION
— FAILURE CODE [CA386] SENSOR POWER SUPPLY (1) ABNORMALLY HIGH LEVEL (LEFT BANK): HIGH VOLTAGE DETECTION
— FAILURE CODE [CB386] SENSOR POWER SUPPLY (1) ABNORMALLY HIGH LEVEL (RIGHT BANK): HIGH VOLTAGE DETECTION
— FAILURE CODE [CA431] TROUBLE IN IDLE VALIDATION SWITCH
— FAILURE CODE [CA432] IDLE VALIDATION ACTION ERROR
— FAILURE CODE [CA441] POWER SUPPLY VOLTAGE ABNORMALLY LOW LEVEL (LEFT BANK): LOW VOLTAGE DETECTION
— FAILURE CODE [CB441] POWER SUPPLY VOLTAGE ABNORMALLY LOW LEVEL (RIGHT BANK): LOW VOLTAGE DETECTION
— FAILURE CODE [CA442] POWER SUPPLY VOLTAGE ABNORMALLY HIGH LEVEL (LEFT BANK): HIGH VOLTAGE DETECTION
— FAILURE CODE [CB442] POWER SUPPLY VOLTAGE ABNORMALLY HIGH LEVEL (RIGHT BANK): HIGH VOLTAGE DETECTION
— FAILURE CODE [CA449] COMMON RAIL ABNORMALLY HIGH PRESSURE (2) (LEFT BANK): ABNORMALLY HIGH PRESSURE OCCURRENCE
— FAILURE CODE [CB449] COMMON RAIL ABNORMALLY HIGH PRESSURE (2) (RIGHT BANK): ABNORMALLY HIGH PRESSURE OCCURRENCE
— FAILURE CODE [CA451] COMMON RAIL PRESSURE SENSOR TOO HIGH (AT LEFT BANK): EXCESSIVELY HIGH VOLTAGE DETECTED
— FAILURE CODE [CB451] COMMON RAIL PRESSURE SENSOR ABNORMALLY HIGH LEVEL (RIGHT BANK): HIGH VOLTAGE DETECTION
— FAILURE CODE [CA452] COMMON RAIL PRESSURE SENSOR ABNORMALLY LOW LEVEL (LEFT BANK): ABNORMALLY LOW VOLTAGE DETECTION
— FAILURE CODE [CB452] COMMON RAIL PRESSURE SENSOR ABNORMALLY LOW LEVEL (RIGHT BANK): ABNORMALLY LOW VOLTAGE DETECTION
— FAILURE CODE [CA553] COMMON RAIL PRESSURE TOO HIGH (1) (AT LEFT BANK): EXCESSIVELY HIGH PRESSURE DETECTED
— FAILURE CODE [CB553] COMMON RAIL PRESSURE TOO HIGH (1) (AT RIGHT BANK): EXCESSIVELY HIGH PRESSURE DETECTED
— FAILURE CODE [CA554] IN-RANGE ERROR IN COMMON RAIL PRESSURE SENSOR (AT LEFT BANK): IN-RANGE ERROR
— FAILURE CODE [CB554] IN-RANGE ERROR IN COMMON RAIL PRESSURE SENSOR (AT RIGHT BANK): IN-RANGE ERROR
— FAILURE CODE [CA559] LOSS OF PRESSURE FEED FROM SUPPLY PUMP (1) (AT LEFT BANK): LOSS OF PRESSURE FEED DETECTED
— FAILURE CODE [CB559] LOSS OF PRESSURE FEED FROM SUPPLY PUMP (1) (AT RIGHT BANK): LOSS OF PRESSURE FEED DETECTED
— FAILURE CODE [CA689] ABNORMAL ENGINE NE SPEED SENSOR (AT LEFT BANK): ABNORMAL SIGNAL
— FAILURE CODE [CB689] ABNORMAL ENGINE NE SPEED SENSOR (AT RIGHT BANK): ABNORMAL SIGNAL
— FAILURE CODE [CA691] INTAKE AIR TEMPERATURE SENSOR ABNORMALLY HIGH LEVEL (ONLY LEFT BANK): HIGH VOLTAGE DETECTION
— FAILURE CODE [CA692] INTAKE AIR TEMPERATURE SENSOR ABNORMALLY LOW LEVEL (ONLY LEFT BANK): LOW VOLTAGE DETECTION
— FAILURE CODE [CA731] ABNORMAL ENGINE BKUP SPEED SENSOR PHASE (AT LEFT BANK): ABNORMAL PHASE
— FAILURE CODE [CB731] ABNORMAL ENGINE BKUP SPEED SENSOR PHASE (AT RIGHT BANK): ABNORMAL PHASE
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 4
— FAILURE CODE [CA757] LOSS OF ALL ENGINE CONTROLLER DATA (AT LEFT BANK): LOSS OF ALL DATA
— FAILURE CODE [CB757] LOSS OF ALL ENGINE CONTROLLER DATA (AT RIGHT BANK): LOSS OF ALL DATA
— FAILURE CODE [CA778] ENGINE BKUP SPEED SENSOR ABNORMALITY (AT LEFT BANK): BKUP SIGNAL ERROR
— FAILURE CODE [CB778] ENGINE BKUP SPEED SENSOR ABNORMALITY (RIGHT BANK): BKUP SIGNAL ERROR
— FAILURE CODE [CA781] INTER-MULTICONTROLLER COMMUNICATION ERROR (LEFT BANK): COMMUNICATION ERROR
— FAILURE CODE [CB781] INTER-MULTICONTROLLER COMMUNICATION ERROR (RIGHT BANK): COMMUNICATION ERROR
— FAILURE CODE [CA1257] MULTICONTROLLER DISTINCTION WIRING HARNESS KEY ERROR (LEFT BANK): DISTINCTION ERROR
— FAILURE CODE [CB1257] MULTICONTROLLER DISTINCTION WIRING HARNESS KEY ERROR (RIGHT BANK): DISTINCTION ERROR
— FAILURE CODE [CB1548] INJECTOR #7 (R/B #1) SYSTEM DISCONNECTION/SHORT CIRCUIT (RIGHT BANK): DISCONNECTION/SHORT CIRCUIT
— FAILURE CODE [CB1549] INJECTOR #8 (R/B #2) SYSTEM DISCONNECTION/SHORT CIRCUIT (RIGHT BANK): DISCONNECTION/SHORT CIRCUIT
— FAILURE CODE [CB1551] INJECTOR #10 (R/B #4) SYSTEM DISCONNECTION/SHORT CIRCUIT (RIGHT BANK): DISCONNECTION/SHORT CIRCUIT
— FAILURE CODE [CB1552] INJECTOR #11 (R/B #5) SYSTEM DISCONNECTION/SHORT CIRCUIT (RIGHT BANK): DISCONNECTION/SHORT CIRCUIT
— FAILURE CODE [CB1553] INJECTOR #12 (R/B #6) SYSTEM DISCONNECTION/SHORT CIRCUIT (RIGHT BANK): DISCONNECTION/SHORT CIRCUIT
— FAILURE CODE [CB1622] INJECTOR #9 (R/B #3) SYSTEM DISCONNECTION/SHORT CIRCUIT (RIGHT BANK): DISCONNECTION/SHORT CIRCUIT
— FAILURE CODE [CA1633] KOMNET ABNORMALITY (LEFT BANK): COMMUNICATION ERROR
— FAILURE CODE [CA2185] THROTTLE SENSOR POWER SUPPLY ABNORMALLY HIGH LEVEL (ONLY LEFT BANK): HIGH VOLTAGE DETECTION
— FAILURE CODE [CA2186] THROTTLE SENSOR POWER SOURCE TOO LOW (AT LEFT BANK ONLY): EXCESSIVELY LOW VOLTAGE DETECTET
— FAILURE CODE [CA2249] LOSS OF PRESSURE FEED FROM SUPPLY PUMP (2) (AT LEFT BANK): LOSS OF PRESSURE FEED DETECTED
— FAILURE CODE [CB2249] LOSS OF PRESSURE FEED FROM SUPPLY PUMP (2) (AT RIGHT BANK): LOSS OF PRESSURE FEED DETECTED
— FAILURE CODE [CA2555] INTAKE HEATER RELAY VOLTAGE LOW ERROR (LEFT BANK ONLY)
— FAILURE CODE [CA2556] INTAKE HEATER RELAY VOLTAGE HIGH ERROR (LEFT BANK ONLY)
— FAILURE CODE [D160KZ] (OR TM & AJSS CONTROLLER LED DISPLAY [10], ABNORMALITY IN BACKUP LAMP RELAY SYSTEM: DISCONNECTION, SHORT CIRCUIT OR HOT SHORT CIRCUIT
— FAILURE CODE [D180KA] (PREHEATING RELAY OUTPUT SYSTEM: DISCONNECTION)
— FAILURE CODE [D180KB] (PREHEATING RELAY OUTPUT SYSTEM: GROUNDING FAULT)
— FAILURE CODE [D180KY] (PREHEATING RELAY OUTPUT SYSTEM: HOT SHORT CIRCUIT)
— FAILURE CODE [D19AKB] (OR TM & AJSS CONTROLLER LED DISPLAY [56], ABNORMALITY IN JOYSTICK CAUTION RELAY OUTPUT SYSTEM: DISCONNECTION OR SHORT CIRCUIT)
— FAILURE CODE [D19BKZ] (OR TM & AJSS CONTROLLER LED DISPLAY [62], ABNORMALITY IN JOYSTICK NEUTRAL INTERLOCK RELAY OUTPUT SYSTEM: DISCONNECTION OR SHORT CIRCUIT)
— FAILURE CODE [D1EFKA] (PRE-LUBRICATION START RELAY OUTPUT SYSTEM: DISCONNECTION)
— FAILURE CODE [D1EFKB] (PRE-LUBRICATION START RELAY OUTPUT SYSTEM: GROUNDING FAULT)
— FAILURE CODE [D1EFKY] (PRE-LUBRICATION START RELAY OUTPUT SYSTEM: HOT SHORT CIRCUIT)
— FAILURE CODE [D1EHKA] (ENGINE START RELAY OUTPUT SYSTEM: DISCONNECTION)
— FAILURE CODE [D1EHKB] (ENGINE START RELAY OUTPUT SYSTEM: GROUNDING FAULT)
— FAILURE CODE [D1EHKY] (ENGINE START RELAY OUTPUT SYSTEM: HOT SHORT CIRCUIT)
— FAILURE CODE [D5ZHL6] (STARTING SWITCH TERMINAL C SIGNAL: ERROR)
— FAILURE CODE [D5ZSKA] (MACHINE MONITOR COMMUNICATION OUTPUT: DISCONNECTION)
— FAILURE CODE [D5ZSKB] (MACHINE MONITOR COMMUNICATION OUTPUT: GROUNDING FAULT)
— FAILURE CODE [D5ZSKY] (MACHINE MONITOR COMMUNICATION OUTPUT: HOT SHORT CIRCUIT)
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 5
— FAILURE CODE [DB2RKR] (ENGINE CONTROLLER CAN-NET COMMUNICATION: DISCONNECTION AND GROUNDING FAULT)
— FAILURE CODE [DBB0KK] (OR VHMS LED DISPLAY: “n9” → “01”, VHMS CONTROLLER: LOW SUPPLY VOLTAGE)
— FAILURE CODE [DBB0KQ] (OR VHMS LED DISPLAY: “nF” → “11”, VHMS CONTROLLER MODEL SELECTION: DISAGREEMENT OF MODEL SELECTION SIGNALS)
— FAILURE CODE [DBB3KK] (OR VHMS LED DISPLAY: “n9” → “05”, VHMS CONTROLLER: LOW DIRECT SUPPLY VOLTAGE)
— FAILURE CODE [DBB5KP] (OR VHMS LED DISPLAY: “n9” → “04”, VHMS CONTROLLER SENSOR POWER SUPPLY (5 V): LOW OUTPUT VOLTAGE)
— FAILURE CODE [DBB6KP] (OR VHMS LED DISPLAY: “n9” → “02”, VHMS CONTROLLER SENSOR POWER SUPPLY (24 V): LOW OUTPUT VOLTAGE)
— FAILURE CODE [DBBQKR] (OR VHMS LED DISPLAY: “n8” → “02”, VHMS CONTROLLER CAN COMMUNICATION ABNORMALITY)
— FAILURE CODE [DBG2KK] (SOLENOID POWER SUPPLY: LOW VOLTAGE)
— FAILURE CODE [DBG3KK] (BATTERY DIRECT POWER SUPPLY: LOW VOLTAGE)
— FAILURE CODE [DBG9KQ] (MODEL SELECTION SIGNAL: ABNORMAL)
— FAILURE CODE [DBGRKR] (PRE-LUBRICATION CONTROLLER CAN-NET COMMUNICATION: DISCONNECTION OR GROUNDING FAULT)
— FAILURE CODE [DDE2KB] (ENGINE OIL PRESSURE SWITCH ERROR: GROUNDING FAULT)
— FAILURE CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH ERROR: DISCONNECTION OR HOT SHORT CIRCUIT)
— FAILURE CODE [DDK3KZ] (OR TM & AJSS CONTROLLER LED DISPLAY [20], ABNORMALITY IN JOYSTICK FORWARD-REVERSE SWITCH SYSTEM: DISCONNECTION OR HOT SHORT CIRCUIT)
— FAILURE CODE [DDK5KZ] (OR TM & AJSS CONTROLLER LED DISPLAY: “21”, ABNORMALITY IN SHIFTING UP/DOWN SWITCH SYSTEM: DISCONNECTION, SHORT CIRCUIT OR HOT SHORT CIRCUIT)
— FAILURE CODE [DDP5KZ] (ABNORMALITY IN STEERING LOCK SWITCH SYSTEM: DISCONNECTION OR SHORT CIRCUIT)
— FAILURE CODE [DGE5KX] (ATMOSPHERIC TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE (SHORT))
— FAILURE CODE [DGH2KX] (HYDRAULIC OIL TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE (SHORT))
— FAILURE CODE [DGR4KX] (FRONT BRAKE OIL TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE (SHORT))
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 6
— FAILURE CODE [DGT5KA] (OR VHMS LED DISPLAY: “n3” → “12”, L.H. BANK EXHAUST GAS TEMPERATURE SENSOR SYSTEM (FRONT): DISCONNECTION OR SHORT CIRCUIT)
— FAILURE CODE [dGT5KA] (OR VHMS LED DISPLAY: “n3” → “22”, L.H. BANK EXHAUST GAS TEMPERATURE SENSOR SYSTEM (REAR): DISCONNECTION OR SHORT CIRCUIT)
— FAILURE CODE [DGT5KB] (OR VHMS LED DISPLAY: “n3” → “11”, L.H. BANK EXHAUST GAS TEMPERATURE SENSOR SYSTEM (FRONT): HOT SHORT CIRCUIT)
— FAILURE CODE [dGT5KB] (OR VHMS LED DISPLAY: “n3” → “21”, L.H. BANK EXHAUST GAS TEMPERATURE SENSOR SYSTEM (REAR): HOT SHORT CIRCUIT)
— FAILURE CODE [DGT6KA] (OR VHMS LED DISPLAY: “n3” → “24”, R.H. BANK EXHAUST GAS TEMPERATURE SENSOR SYSTEM (FRONT): DISCONNECTION OR SHORT CIRCUIT)
— FAILURE CODE [dGT6KA] (OR VHMS LED DISPLAY: “n3” → “26”, R.H. EXHAUST GAS TEMPERATURE SENSOR SYSTEM (REAR): DISCONNECTION OR SHORT CIRCUIT)
— FAILURE CODE [DGT6KB] (OR VHMS LED DISPLAY “n3” → “23”, R.H. BANK EXHAUST GAS TEMPERATURE SENSOR SYSTEM (FRONT): HOT SHORT CIRCUIT)
— FAILURE CODE [dGT6KB] (OR VHMS LED DISPLAY “n3” → “25”, R.H. BANK EXHAUST GAS TEMPERATURE SENSOR SYSTEM (REAR): HOT SHORT CIRCUIT)
— FAILURE CODE [DHE5KB] (OR VHMS_LED DISPLAY: “n3” → “32”, BLOW-BY PRESSURE SENSOR SYSTEM: SHORT CIRCUIT)
— FAILURE CODE [DHE5KY] (OR VHMS LED DISPLAY: “n3” → “31”, BLOW-BY PRESSURE SENSOR SYSTEM: HOT SHORT CIRCUIT)
— FAILURE CODE [DHP2KX] (MAIN PUMP OIL PRESSURE SENSOR ERROR: DISCONNECTION OR SHORT CIRCUIT)
— FAILURE CODE [DHT3KX] (OR VHMS LED DISPLAY: “n6” → “14”, TRANSMISSION OIL PRESSURE SENSOR SYSTEM: OUT OF INPUT SIGNAL RANGE)
— FAILURE CODE [DHT8KX] (STEERING PUMP OIL PRESSURE SENSOR ERROR): DISCONNECTION OR SHORT CIRCUIT)
— FAILURE CODE [DHU2KX] (FRONT BRAKE OIL PRESSURE SENSOR ERROR: DISCONNECTION OR SHORT CIRCUIT)
— FAILURE CODE [DHU3KX] (REAR BRAKE OIL PRESSURE SENSOR ERROR: DISCONNECTION OR SHORT CIRCUIT)
— FAILURE CODE [DK00L8] (OR TM & AJSS CONTROLLER LED DISPLAY [58], STEERING AND FRAME ANGLE DISPLACEMENT)
— FAILURE CODE [DK30KX] (OR TM & AJSS CONTROLLER LED DISPLAY [57], ABNORMALITY IN STEERING ANGLE POTENTIOMETER SYSTEM): DISCONNECTION OR SHORT CIRCUIT)
— FAILURE CODE [DKD0KX] (OR TM & AJSS CONTROLLER LED DISPLAY [59], ABNORMALITY IN FRAME ANGLE POTENTIOMETER SYSTEM: DISCONNECTION OR SHORT CIRCUIT)
— FAILURE CODE [DLE4KA] (OR TM & AJSS CONTROLLER LED DISPLAY [23], ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM: DISCONNECTION, SHORT CIRCUIT OR HOT SHORT CIRCUIT)
— FAILURE CODE [DLT4KA] (OR TM & AJSS CONTROLLER LED DISPLAY [22], ABNORMALITY IN SPEED SENSOR SYSTEM: DISCONNECTION, SHORT CIRCUIT OR HOT SHORT CIRCUIT)
— FAILURE CODE [DUM7KY] (PRE-LUBRICATION OPERATION LAMP OUTPUT ABNORMALITY: HOT SHORT CIRCUIT)
— FAILURE CODE [DUM7KZ] (PRE-LUBRICATION OPERATION LAMP OUTPUT ABNORMALITY: DISCONNECTION OR GROUNDING FAULT)
— FAILURE CODE [DXF0KZ] (OR TM & AJSS CONTROLLER LED DISPLAY [63], ABNORMALITY IN JOYSTICK EPC SOLENOID SYSTEM: DISCONNECTION, SHORT CIRCUIT OR HOT SHORT CIRCUIT)
— FAILURE CODE [DXH4KZ] (OR TM & AJSS CONTROLLER LED DISPLAY [14], ABNORMALITY IN 1ST SOLENOID SYSTEM: DISCONNECTION, SHORT CIRCUIT OR HOT SHORT CIRCUIT)
— FAILURE CODE [DXH5KZ] (OR TM & AJSS CONTROLLER LED DISPLAY [15], ABNORMALITY IN 2ND SOLENOID SYSTEM: DISCONNECTION, SHORT CIRCUIT OR HOT SHORT CIRCUIT)
— FAILURE CODE [DXH6KZ] (OR TM & AJSS CONTROLLER LED DISPLAY [16], ABNORMALITY IN 3RD SOLENOID SYSTEM: DISCONNECTION, SHORT CIRCUIT OR HOT SHORT CIRCUIT)
— FAILURE CODE [DXH7KZ] (OR TM & AJSS CONTROLLER LED DISPLAY [13], ABNORMALITY IN R SOLENOID SYSTEM: DISCONNECTION, SHORT CIRCUIT OR HOT SHORT CIRCUIT)
— FAILURE CODE [DXH8KZ] (OR TM & AJSS CONTROLLER LED DISPLAY [12], ABNORMALITY IN F SOLENOID SYSTEM: DISCONNECTION, SHORT CIRCUIT OR HOT SHORT CIRCUIT)
— FAILURE CODE [F@BBZL] (OR VHMS LED DISPLAY: “n3” → “38”, BLOW-BY PRESSURE SENSOR SYSTEM: HIGH PRESSURE ERROR)
— FAILURE CODE [F@BYNR] (OR VHMS LED DISPLAY: “n3” → “62”, L.H. FRONT EXHAUST GAS TEMPERATURE SENSOR (2): ABNORMAL RISE OF EXHAUST GAS TEMPERATURE)
— FAILURE CODE [f@BYNR] (OR VHMS LED DISPLAY: “n3” → “72”, L.H. REAR EXHAUST GAS TEMPERATURE SENSOR (2): ABNORMAL RISE OF EXHAUST GAS TEMPERATURE)
— FAILURE CODE [F@BYNS] (OR VHMS LED DISPLAY: “n3” → “61”, L.H. FRONT EXHAUST GAS TEMPERATURE SENSOR (1): ABNORMAL RISE OF EXHAUST GAS TEMPERATURE)
— FAILURE CODE [f@BYNS] (OR VHMS LED DISPLAY: “n3” → “71”, L.H. REAR EXHAUST GAS TEMPERATURE SENSOR (1): ABNORMAL RISE OF EXHAUST GAS TEMPERATURE)
— FAILURE CODE [F@BZNR] (OR VHMS LED DISPLAY: “n3” → “82”, R.H. FRONT EXHAUST GAS TEMPERATURE SENSOR (2): ABNORMAL RISE OF EXHAUST GAS TEMPERATURE)
— FAILURE CODE [f@BZNR] (OR VHMS LED DISPLAY: “n3” → “92”, R.H. REAR EXHAUST GAS TEMPERATURE SENSOR (2): ABNORMAL RISE OF EXHAUST GAS TEMPERATURE)
— FAILURE CODE [F@BZNS] (OR VHMS LED DISPLAY: “n3” → “38”, R.H. FRONT EXHAUST GAS TEMPERATURE SENSOR (1): ABNORMAL RISE OF EXHAUST GAS TEMPERATURE)
— FAILURE CODE [f@BZNS] (OR VHMS LED DISPLAY: “n3” → “39”, R.H. REAR EXHAUST GAS TEMPERATURE SENSOR (1): ABNORMAL RISE OF EXHAUST GAS TEMPERATURE)
– TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
— E-1 ENGINE DOES NOT START
— E-2 ABNORMALITY IN PREHEATING SYSTEM
— E-3 TRANSMISSION AND AJSS CONTROLLER DOES NOT WORK
— E-4 TRANSMISSION AND AJSS CONTROLLER MODEL SELECTION ERROR
— E-5 PARKING BRAKE DOES NOT WORK (AS THE EMERGENCY BRAKE)
— E-6 PARKING BRAKE IS APPLIED WHILE MACHINE IS TRAVELING
— E-7 PARKING BRAKE IS RELEASED AS STARTING SWITCH IS TURNED ON
— E-8 SETTING TO THE NEUTRAL POSITION BECOMES UNAVAILABLE WHILE THE PARKING BRAKE IS IN OPERATION (PARKING BRAKE OPERATES NORMALLY)
— E-9 PARKING BRAKE REMAINS IN THE NEUTRAL AND NOT REMOVABLE TO OTHER POSITION (WHEN PARKING BRAKE IS NOT APPLIED)
— E-10 DEFECTIVE KICK-DOWN SWITCH
— E-11 DEFECTIVE HOLD SWITCH
— E-12 LIFT ARM (BOOM) KICK-OUT IS UNAVAILABLE
— E-13 BUCKET POSITIONER FUNCTIONAL ERROR
— E-14 ACTIVE WORKING FUNCTIONAL ERROR
— E-15 TURN SIGNAL OR HAZARD DISPLAY DO NOT FLASH
— E-16 SMALL LAMP DOES NOT LIGHT UP
— E-17 HEAD LAMP DOES NOT LIGHT UP
— E-18 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP
— E-19 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP
— E-20 ABNORMALITY IN TRANSMISSION CUT-OFF
— E-21 ABNORMALITY IN LOW IDLE SELECTION
— E-22 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING
— E-23 ABNORMALITY IN BUZZER
– TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
— METHOD OF USING TROUBLESHOOTING CHART
— H-1 MACHINE DOES NOT MOVE
— H-2 MACHINE LACKS POWER OR SPEED (EVERY SPEED RANGE)
— H-3 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR
— H-4 TORQUE CONVERTER OIL TEMPERATURE IS HIGH
— H-5 STEERING DOES NOT TURN
— H-6 TURNING, RESPONSE OF STEERING IS POOR
— H-7 JOYSTICK LEVER IS HEAVY
— H-8 STEERING WHEEL SHAKES OR JERKS
— H-9 MINIMUM TURNING RADII TO RIGHT AND LEFT ARE DIFFERENT
— H-10 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR
— H-11 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG
— H-12 LIFT ARM DOES NOT RISE
— H-13 LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER
— H-14 WHEN RAISING LIFT ARM, BECOMES SLOW AT CERTAIN HEIGHT
— H-15 LIFT ARM CYLINDER CANNOT HOLD DOWN BUCKET
— H-16 LIFT ARM HAS LARGE AMOUNT OF HYDRAULIC DRIFT
— H-17 LIFT ARM FLUCTUATES WHILE WORKING
— H-18 LIFT ARM DROPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO RAISE
— H-19 BUCKET DOES NOT TILT BACK
— H-20 BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER
— H-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK
— H-22 BUCKET CYLINDER CANNOT HOLD DOWN BUCKET
— H-23 BUCKET HAS LARGE AMOUNT OF HYDRAULIC DRIFT
— H-24 BUCKET FLUCTUATES WHILE TRAVELING UNDER LOAD (WORK EQUIPMENT VALVE “HOLD”)
— H-25 BUCKET DUMPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO TILT
— H-26 LIFT ARM AND BUCKET LEVERS DO NOT MOVE SMOOTHLY
– TROUBLESHOOTING OF ENGINE (S-MODE)
— METHOD OF USING TROUBLESHOOTING CHART
— S-1 STARTING PERFORMANCE IS POOR
— S-2 ENGINE DOES NOT START
— S-3 ENGINE DOES NOT PICK UP SMOOTHLY
— S-4 ENGINE STOPS DURING OPERATIONS
— S-5 ENGINE DOES NOT ROTATE SMOOTHLY
— S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
— S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
— S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
— S-9 OIL BECOMES CONTAMINATED QUICKLY
— S-10 FUEL CONSUMPTION IS EXCESSIVE
— S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)
— S-12 OIL PRESSURE DROPS
— S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL)
— S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
— S-15 ABNORMAL NOISE IS MADE
— S-16 VIBRATION IS EXCESSIVE
– TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M-MODE)
— MACHINE MONITOR SYSTEM
— M-1 MACHINE MONITOR DOES NOT WORK
— M-2 ENGINE STARTS IMMEDIATELY AFTER (WITHIN 3 SEC OF) TURNING STARTING SWITCH ON, BUT ALL THE MACHINE MONITORS REMAIN LIT
— M-3 SPEEDOMETER DISPLAY DOES NOT WORK
— M-4 SHIFT INDICATOR ERROR
— M-5 MONITOR TURN SIGNAL (HAZARD) INDICATOR DOES NOT LIGHT UP
— M-6 PARKING INDICATION ERROR
— M-7 ABNORMALITY IN PREHEATING SYSTEM
— M-8 NIGHT LAMP DOES NOT LIGHT UP
— M-9 FRONT WORK LAMP ERROR
— M-10 REAR WORK LAMP ERROR
— M-11 ABNORMALITY IN TRANSMISSION CUT-OFF SWITCH
— M-12 ABNORMALITY IN LOW IDLE SELECTION
— M-13 EMERGENCY STEERING INDICATION ERROR
— M-14 PARKING BRAKE DRAGGING WARNING ERROR
— M-15 BUZZER AND CAUTION LAMP ERROR UPON PARKING BRAKE DRAGGING WARNING OUTPUTTING
— M-16 BUZZER ERROR
— M-17 SWITCHING STATE OF MACHINE MONITOR IS NOT STORED
— M-18 FAILURE INDICATION MODE ERROR
— M-19 MACHINE MONITOR DOES NOT INDICATE FAILURE CODE
— M-20 ABNORMALITY IN AUTO GREASE SYSTEM
– TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE)
— MAINTENANCE MONITOR SYSTEM
— K-1 MAINTENANCE MONITOR DOES NOT WORK
— K-2 IMMEDIATELY AFTER TURNING STARTING SWITCH ON (WITHIN 3 SEC.), ENGINE STARTS BUT THE MAINTENANCE MONITOR REMAINS FULLY LIT UP
— K-3 WORK CHECK ITEM FLASHES UPON TURNING STARTING SWITCH ON (ENGINE NOT RUNNING)
— K-4 CAUTION ITEM FLASHES UPON TURNING STARTING SWITCH ON (ENGINE RUNNING)
— K-5 THE WARNING BUZZER DOES NOT SOUND WHILE CAUTION ITEM INDICATOR FLASHES
— K-6 THE WARNING BUZZER SOUNDS WHILE MONITOR INDICATES NO ERROR
— K-7 THE WARNING LAMPS (CHECK LAMP AND CAUTION LAMP) DO NOT FLASH WHILE CAUTION ITEM INDICATOR FLASHES
— K-8 WARNING LAMPS (CHECK AND CAUTION LAMPS) LIGHTS UP WHILE THE MAINTENANCE MONITOR INDICATES NO ERROR
— K-9 NIGHT LAMP DOES NOT LIGHT UP
— K-10 NIGHT LAMP REMAINS LIT UP
— K-11 SERVICE METER DOES NOT WORK
— K-12 SERVICE METER KEEPS ON WORKING (WHEN ENGINE STOPS)
— K-13 GAUGE ITEMS (FUEL, ENGINE COOLANT TEMPERATURE AND TORQUE CONVERTER OIL TEMPERATURE) ERROR
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 (SAA12V140E-3)
— REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
— REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
— REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF DAMPER ASSEMBLY
— REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
– ENGINE (SAA12V140E-3)
— REMOVAL AND INSTALLATION OF RIGHT BANK FUEL SUPPLY PUMP ASSEMBLY
— REMOVAL AND INSTALLATION OF LEFT BANK FUEL SUPPLY PUMP ASSEMBLY
— REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
— REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
— REMOVAL AND INSTALLATION OF ENGINE FRONT OIL SEAL
— REMOVAL AND INSTALLATION OF ENGINE REAR OIL SEAL
– POWER TRAIN, PART 1
— DISASSEMBLY AND ASSEMBLY OF TRANSFER ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY
— REMOVAL AND INSTALLATION OF PARKING BRAKE CALIPERS ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE CALIPERS ASSEMBLY
— REMOVAL AND INSTALLATION OF PARKING BRAKE PAD
— REMOVAL AND INSTALLATION OF PARKING BRAKE SPRING CYLINDER
— REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY
– POWER TRAIN, PART 2 (TORQUE CONVERTER AND TRANSMISSION)
— DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY
– POWER TRAIN, PART 3 (AXLE AND FINAL DRIVE)
— 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
— REMOVAL AND INSTALLATION OF DIFFERENTIAL ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
– BRAKE SYSTEM
— REMOVAL AND INSTALLATION OF BRAKE ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF BRAKE ASSEMBLY
— REMOVAL AND INSTALLATION OF LEFT BRAKE VALVE ASSEMBLY
— REMOVAL AND INSTALLATION OF RIGHT BRAKE VALVE ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF ACCUMULATOR CHARGE VALVE
— DISASSEMBLY AND ASSEMBLY OF SLACK ADJUSTER
– UNDERCARRIAGE AND FRAME
— REMOVAL AND INSTALLATION OF CENTER HINGE PIN
— REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY
– HYDRAULIC SYSTEM
— REMOVAL AND INSTALLATION OF HYDRAULIC TANK AND FILTER CASE ASSEMBLY
— REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY
— REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF PPC VALVE ASSEMBLY
— REMOVAL AND INSTALLATION OF STEERING VALVE ASSEMBLY
— REMOVAL AND INSTALLATION OF DIVERTER VALVE ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF DIVERTER VALVE ASSEMBLY
— REMOVAL AND INSTALLATION OF ORBIT-ROLL ASSEMBLY
— DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
– WORK EQUIPMENT
— REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY
— REPLACEMENT OF BOOM FRONT BUSHING
– CAB AND ITS ATTACHMENTS
— REMOVAL AND INSTALLATION OF OPERATOR CAB ASSEMBLY
— REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY
– ELECTRICAL SYSTEM
— REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY
— REMOVAL AND INSTALLATION OF TRANSMISSION AND STEERING CONTROLLER ASSEMBLY
— REMOVAL AND INSTALLATION OF MAIN MONITOR 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
— ELECTRICAL CIRCUIT DIAGRAM (1/8)
— ELECTRICAL CIRCUIT DIAGRAM (2/8)
— ELECTRICAL CIRCUIT DIAGRAM (3/8)
— ELECTRICAL CIRCUIT DIAGRAM (4/8)
— ELECTRICAL CIRCUIT DIAGRAM (5/8)
— ELECTRICAL CIRCUIT DIAGRAM (6/8)
— ELECTRICAL CIRCUIT DIAGRAM (7/8)
— ELECTRICAL CIRCUIT DIAGRAM (8/8)
— CONNECTOR ARRANGEMENT DIAGRAM
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