Komatsu WA600-6 Galeo Wheel Loader Shop Manual (SN: 60001 and up)

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Komatsu WA600-6 Galeo Wheel Loader Shop Manual (SN: 60001 and up) – SEN00235-05

This Complete Service Repair Workshop Manual PDF Download for the Komatsu WA600-6 Galeo Wheel Loader has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

APPLICABLE MODELS :

Komatsu WA600-6 Galeo Wheel Loader
Serial Numbers : 60001 and up

TABLE OF CONTENTS :

00 INDEX AND FOREWORD
01 SPECIFICATION
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
20 STANDARD VALUE TABLE
30 TESTING AND ADJUSTING
40 TROUBLESHOOTING
50 DISASSEMBLY AND ASSEMBLY
90 DIAGRAMS AND DRAWINGS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : SEN00235-05
Total Pages : 1834

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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 ELETRIC EQUIPMENT AND HYDRAULIC COMPONENT
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
SPECIFICATON DIMENSION DRAWING
SPECIFICATIONS
WEIGHT TABLE
TABLE OF FUEL, COOLANT AND LUBRICANTS
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE ANF COOLING SYSTEM
ENGINE MOUNT AND TRANSMISSION MOUNT
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 SIAGRAM
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
BUCKER POSITIONER AND BOOM KICK-OUT
WORK EQUIPMENT LUBRICATION
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 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 SYSTEM
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
SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS)
VHMS CONTROLLER INITIAL SETTING PROCEDURE
PRECAUTIONS FOR REPLACING VHMS CONTROLLER
PM-CLICK INSPECTION TABLE
40 TROUBLESHOOTING
GENERAL INFORMATION ON TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
TESTING BEFORE TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 1
FAILURE CODES LIST
BEFORE CARRYING OUT TROUBLESHOOTING FOR ELECTRICAL SYSTEM
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
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 MODULE 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 [[email protected]] (ROTATION DERATING BY LOW ENGINE OIL PRESSURE)
FAILURE CODE [[email protected]] (ENGINE OIL: LOW LEVEL)
FAILURE CODE [[email protected]] (ENGINE OVERHEATING)
FAILURE CODE [[email protected]] (COOLANT: LOW LEVEL)
FAILURE CODE [[email protected]] (BRAKE OIL: OVERHEATING)
FAILURE CODE [[email protected]] (TORQUE CONVERTER OIL: OVERHEATING)
FAILURE CODE [[email protected]] (BATTERY ELECTROLYTE: LOW LEVEL)
FAILURE CODE [[email protected]] (HYDRAULIC OIL: OVERHEATING)
FAILURE CODE [CA111] (ABNORMALITY IN ENGINE CONTROLLER)
FAILURE CODE [CA115] (ENGINE NE OR BKUP SPEED SENSOR ERROR)
FAILURE CODE [CA122] (CHARGE PRESSURE SENSOR HIGH ERROR)
FAILURE CODE [CA123] (CHARGE 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 TEMPERATURE SENSOR HIGH ERROR)
FAILURE CODE [CA154] (CHARGE 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 (L/B #1) OPEN/SHORT ERROR)
FAILURE CODE [CA323] (INJECTOR #5 (L/B #5) OPEN/SHORT ERROR)
FAILURE CODE [CA324] (INJECTOR #3 (L/B #3) OPEN/SHORT ERROR)
FAILURE CODE [CA325] (INJECTOR #6 (L/B #6) OPEN/SHORT ERROR)
FAILURE CODE [CA331] (INJECTOR #2 (L/B #2) OPEN/SHORT ERROR)
FAILURE CODE [CA332] (INJECTOR #4 (L/B #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 [CA1228] (EGR VALVE SERVO ERROR 1)
FAILURE CODE [CA1625] (EGR VALVE SERVO ERROR 2)
FAILURE CODE [CA1626] (BYPASS VALVE SOLENOID CURRENT HIGH ERROR)
FAILURE CODE [CA1627] (BYPASS VALVE SOLENOID CURRENT LOW ERROR)
FAILURE CODE [CA1628] (BYPASS VALVE SERVO ERROR 1)
FAILURE CODE [CA1629] (BYPASS VALVE SERVO ERROR 2)
FAILURE CODE [CA1631] (BYPASS VALVE LIFT SENSOR HIGH ERROR)
FAILURE CODE [CA1632] (BYPASS VALVE LIFT SENSOR LOW 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 [CA2271] (EGR VALVE LIFT SENSOR HIGH ERROR)
FAILURE CODE [CA2272] (EGR VALVE LIFT SENSOR LOW ERROR)
FAILURE CODE [CA2351] (EGR VALVE SOLENOID OPERATION SHORT CIRCUIT)
FAILURE CODE [CA2352] (EGR VALVE SOLENOID OPERATION DISCONNECT)
FAILURE CODE [CA2555] (INTAKE HEATER RELAY VOLTAGE LOW ERROR)
FAILURE CODE [CA2556] (INTAKE HEATER RELAY VOLTAGE HIGH 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 WLITH 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] (LODA METER SUBTOTAL SWITCH: SWITCH IS KEPT PRESSED FOR LONG TIME)
FAILURE CODE [DD1FLD] (LODA METER MODE SELECTOR SWITCH (A/B): SWITCH IS KEPT PRESSED FOR LONG TIME)
FAILURE CODE [DD1GLD] (LODA METER MODE SELECTOR SWITCH (+/-): SWITCH IS KEPT PRESSED FOR LONG TIME)
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 6
FAILURE CODE [DD1HLD] (LODA 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] (LODA 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 SOSITION)
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 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 [[email protected]] (OR VHMS_LED DISPLAY: “n3″→”38”) (BLOW-BY PRESSURE: HIGH ERROR)
FAILURE CODE [[email protected]] (OR VHMS_LED DISPLAY: “n3″→”62”) (EXHAUST GAS TEMPERATURE (F): ABNORMAL HEAT)
FAILURE CODE [[email protected]] (OR VHMS_LED DISPLAY: “n3″→”61”) (EXHAUST GAS TEMPERATURE (F): OVERHEAT)
FAILURE CODE [[email protected]] (OR VHMS_LED DISPLAY: “n3″→”72”) (EXHAUST GAS TEMPERATURE (R): ABNORMAL HEAT)
FAILURE CODE [[email protected]] (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
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
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
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
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 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

 

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