Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA380, WA380Z Series, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Wheel Loader WA380-, WA380Z-series workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

CEBM017402 - Wheel Loader WA380-6 Shop Manual.pdf
CEBM017403 - Wheel Loader WA380-6 Shop Manual.pdf
CEBM022703 - Wheel Loader WA380-6 Shop Manual.pdf
CEBM025604 - Wheel Loader WA380-7 Shop Manual.pdf
CEBMW23091 - Wheel Loader WA380-3 Shop Manual.pdf
GSBM006102 - Cargadora Avance WA380-3 Manual de Taller.pdf
SEBM006104 - Wheel Loader WA380-3 Loader avance Shop Manual.pdf
SEBM024711 - Wheel Loader WA380-5 Shop Manual.pdf
SEBM024712 - Wheel Loader WA380-5 Shop Manual.pdf
SEBMU4230106 - Wheel Loader WA380-1 Shop Manual.pdf
SEN00769-03 - Wheel Loader WA380-6 Shop Manual.pdf
SEN05650-03 - Wheel Loader WA380-7 Shop Manual.pdf
SEN06411-00 - Wheel Loader WA380-6, WA380Z-6 Shop Manual.pdf
SEN06411-02 - Wheel Loader WA380-6, WA380Z-6 Shop Manual.pdf
SEN06573 - Wheel Loader WA380-8 Shop Manual.pdf
VEBM440101 - Wheel Loader WA380-6 Shop Manual.pdf
VEBM440102 - Wheel Loader WA380-6 Shop Manual.pdf
VEBM460104 - Wheel Loader WA380-3 Shop Manual.pdf
TEN00089-03 - Wheel Loader WA380-5 Operation & Maintenance Manual.pdf
TEN00127-07 - Wheel Loader WA380-6 Operation & Maintenance Manual.pdf
TEN00490-02 - Wheel Loader WA380-6 Operation & Maintenance Manual.pdf
TEN00534-05 - Wheel Loader WA380-7 Operation & Maintenance Manual.pdf
SEAM005801 - Wheel Loader WA380-3 Operation & Maintenance Manual.pdf
SEAMU4230101 - Wheel Loader WA380-1 Operation & Maintenance Manual.pdf
SEAMU4230104 - Wheel Loader WA380-1, WA420-1 Operation & Maintenance Manual.pdf
SEAMU4230106 - Wheel Loader WA380-1, WA420-1 Operation & Maintenance Manual.pdf
CEAM003600 - Wheel Loader WA380-3 avance plus Operation & Maintenance Manual.pdf
CEAM017204 - Wheel Loader WA380-6 Operation & Maintenance Manual.pdf
CEAM023202 - Wheel Loader WA380-6 Operation & Maintenance Manual.pdf
CEAM025804 - Wheel Loader WA380-7 Operation & Maintenance Manual.pdf
CEAMW23090 - Wheel Loader WA380-3 Operation & Maintenance Manual.pdf
GEN00114-00 - Wheel Loader WA380-7 Field Assembly Instruction.pdf

Total Pages: 13,532 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
CEBM017402 - Wheel Loader WA380-6 Shop Manual...2
  CEBM017402 - WA380-6 sn A53001 and UP...2
    CONTENTS...3
    REVISED PAGES...4
    SAFETY...20
      Safety Notice...20
        IMPORTANT SAFETY NOTICE...20
        General Precautions...20
        Preparations for Work...21
        Precautions During Work...21
    GENERAL...22
    HOW TO READ THE SHOP MANUAL...23
      Volumes...23
      Distribution and Updating...23
      Filing Method...23
      Revised Edition Mark...23
      Revisions...23
      Symbols...23
    HOISTING INSTRUCTIONS...24
      Hoisting...24
      Making Signs...24
      Precautions...24
        Precautions for Sling Work...24
        Precautions for Using Mobile Crane...25
        Precautions for Using Overhead Hoist Crane...25
      Selecting Wire Ropes...26
    AIR CONDITIONER CIRCUITS...27
      Precautions for Handling Hoses and Tubes...27
        Disconnecting Hoses and Tubes...27
        Connecting Hoses and Tubes...27
    MAINTENANCE STANDARD TERMS...28
      Handling Connectors Used for Engines...30
        Slide Lock Type...30
        Pull Lock Type...31
        Push Lock Type...31
        Turn-housing Type (Round Green Connector)...33
    PRECAUTIONS FOR OPERATIONS...34
      Precautions when Carrying Out Removal Work...34
      Precautions when Carrying Out Installation Work...35
      Precautions when Completing the Operation...36
    PUSH-PULL COUPLER...37
      Type 1...37
        Disconnection...37
        Connection...37
      Type 2...38
        Disconnection...38
        Connection...38
      Type 3...39
        Disconnection...39
        Connection...39
    COATING MATERIALS...40
    STANDARD TIGHTENING TORQUE...42
      Standard Tightening Tables...42
        For Bolts and Nuts...42
        For Split Flange Bolts...43
        For O-Ring Boss Piping Joints...43
        For O-Ring Boss Plugs...44
        For Hoses (Taper-Seal Type and Face-Seal Type)...44
        For Face Seal Joints...45
        For 102, 107, and 114 Engine Series (Bolts and Nuts)...45
        For 102, 107, and 114 Engine Series (Eye Joints)...45
        For 102, 107, and 114 Engine Series (Taper Screws)...46
    CONVERSION TABLES...47
      Method of Using the Conversion Table...47
  01 GENERAL...54
    SPECIFICATIONS...56
      Dimension Drawing...56
      Specification Tables...58
    WEIGHT TABLE...63
    FUEL, COOLANT, AND LUBRICANTS...65
  10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD...68
    ENGINE AND COOLING SYSTEM...73
      Engine and Transmission Mounting...73
      Cooling System...75
      Cooling Fan Pump...77
      Servo Valve...82
      Cooling Fan Motor System...85
      Hydraulic Motor...88
      Suction Valve...89
      Reversible Valve...90
      Safety Valve...91
    POWER TRAIN SYSTEM...92
      Drive Line Components...92
      System Diagram...93
      Drive Shaft System...95
      Power Train Piping System...96
      Torque Converter...97
        Without Lockup Clutch...97
        Power Transmitting Route...99
        Oil Flow...99
        With Lockup Clutch...100
      Torque Flow...103
        When Lockup Clutch Is Disengaged...103
        When Lockup Clutch Is Engaged...103
        Oil Flow...104
      Transmission...105
        With Lockup Clutch...105
      Forward and Reverse Clutches...115
        Without Lockup Clutch...115
        With Lockup Clutch...116
        1st and 4th Clutches...117
        2nd and 3rd Clutches...118
        Operation of Clutch Pack...119
      Transmission Torque Flow Route...121
        Forward 1st Gear Speed...121
        Forward 2nd Gear Speed...123
        Forward 3rd Gear Speed...125
        Forward 4th Gear Speed...127
        Reverse 1st Gear Speed...129
      Flow Control Valve...131
        Valve Assembly...133
      ECMV System...135
        For R, 1st, and 2nd Clutches...135
        For F, 3rd, 4th, and Lockup Clutches...137
        ECMV For Gear Speed Clutch...139
        ECMV for Lockup Clutch...142
      Main and Torque Converter Relief Valve System...145
        Outline...147
        Operation...147
    DRIVE AXLE SYSTEM...148
      Front Axle Assembly...148
      Rear Axle Assembly...149
      Front Differential...151
      Rear Differential...153
      Limited Slip Differential...156
      Front Axle Carrier...157
      Rear Axle Carrier...159
      Final Drive...163
    STEERING SYSTEM...165
      Steering Piping Diagram...165
      Steering Column...166
      Steering Pump...167
        Pump Unit...169
        Servo Valve...174
        LS Valve...177
        PC Valve...177
      Steering Valve...181
        Operation of Flow Amplifier...185
        Operation of Flow Control Spool...187
        Operation of Steering Valve...189
        Steering Relief Valve...192
        Overload Relief Valve...193
        Relief Valve...194
      Orbitrol Valve...195
      Stop Valve...199
      Steering Relief Valve...200
      Steering Cylinder...201
      Emergency Steering Motor...203
      Emergency Steering Pump (If Equipped)...204
      Joystick Steering Lever Linkage...205
      Steering Electric Lever...206
      Joystick EPC Valve...207
      Multi-Function Lever and Joystick Lever (Modification)...208
    SERVICE BRAKING SYSTEM...210
      Brake Piping Diagram...210
      Charge Valve...211
      Brake Valve...219
      Accumulator (for Brakes)...224
      Front Brake...225
      Rear Brake...227
    PARKING BRAKE SYSTEM...229
      Brake Control...229
      Parking Brake Unit...231
      Parking Brake Solenoid Valve...233
      Emergency Parking Brake Release Valve...235
    UNDERCARRIAGE AND FRAME...236
      Axle Mounting and Center Hinge Pin...236
      Tires...241
    HYDRAULIC SYSTEM...243
      Piping Diagram...243
      Work Equipment Control Lever System...246
      Multi-Function Mono-Lever Type...247
      Hydraulic Tank...249
        Tank Vent System...250
      Power Train Pump...251
      Work Equipment Pump...253
        Pump Unit...255
        Servo Valve...257
        LS Valve...263
        PC valve...264
      Work Equipment Control Valve...267
        4-Spool Valve...269
      CLSS...285
        Outline of CLSS...285
        Basic Principle...286
        Pressure Compensation Control...287
      Function and Operation of Each Valve...288
        Unload Valve...289
        Work Equipment Valve (Supply of LS Pressure)...292
        LS Bypass Plug...294
        Pressure Compensation Valve...295
        Lift Arm Regeneration Circuit...299
        Variable Lift Check Valve...301
        ECSS Control Valve...302
        Accumulator Charge Valve...305
        PPC Valve...309
        Stabilizer Valve...314
        Work Equipment PPC Cutoff Solenoid Valve...319
      Accumulator (for PPC Circuit)...321
      Accumulator (for ECSS)...322
    WORK EQUIPMENT...323
      Work Equipment Linkage...323
      Bucket...325
      Bucket Positioner and Boom Kickout...327
        Bucket Positioner...328
        Boom Kick-out...328
        Proximity Switch...329
      Work Equipment Cylinders...335
        Lift Cylinder...335
        Bucket Cylinder...335
    CAB ENVIRONMENT...336
      ROPS Cab...336
      Air Conditioner...337
        Air Conditioner Piping Diagram...337
        Refrigerant Circuit Diagram...339
        Air Conditioner Unit...340
        Blower and Intake Unit...343
        Refrigerant Compressor...344
        Condenser...345
        Receiver...346
        Air Conditioner Panel...347
    ELECTRICAL SYSTEM...351
      Machine Monitor System...351
        System Circuit Diagram...353
        Machine Monitor...354
        Items Displayed on Monitor...355
      Machine Monitor Operation Switches...364
        Setting Machine Monitor...365
        Troubleshooting Function...365
        Character Display Function...366
        Operator Mode Functions...367
        Service Mode Functions...370
        Input and Output Signals...375
      Transmission Controller System...383
        Gearshifting Control Function...383
        Cooling Fan Control Function...402
        Work Equipment Pump Swash Plate Control Function...407
        Transmission Cutoff Function...409
        ECSS Function...411
        Electric Emergency Steering Function...413
        Directional Selector Switch Control Function...415
        Multi-Function Mono Lever Function...417
        Joystick Steering Function...419
        System Circuit Diagram...422
        Transmission Controller...423
      Work Equipment Controller System...425
        System Circuit Diagram...427
        Work Equipment Controller...429
    ELECTRONIC TRANSMISSION CONTROL...431
      Combination Switch...433
    KICKDOWN AND HOLD SWITCH...435
      Load Meter Cancel Switch and Load Meter Subtotal Switch...435
    MULTI-FUNCTION KNOB...436
      Modification of Multi-Function Lever...437
    JOYSTICK STEERING KNOB...439
    KOMTRAX TERMINAL SYSTEM...440
      KOMTRAX Terminal...441
      Input and Output Signals...442
    ENGINE STARTING CIRCUIT...443
    ENGINE STOPPING CIRCUIT...445
    PREHEATING CIRCUIT...446
    ENGINE POWER MODE SELECTOR CIRCUIT...447
    ENGINE OUTPUT DERATING FUNCTION...448
    AUTOMATIC WARM-UP FUNCTION...448
    PARKING BRAKE CIRCUIT...449
    SENSORS...451
      Speed Sensor...451
      Torque Converter Oil Temperature Sensor...452
      Hydraulic Oil Temperature Sensor...452
      Transmission Oil Temperature Sensor...452
      Brake Oil Temperature Sensor...452
      Work Equipment Pump Oil Pressure Sensor...453
      Steering Pump Oil Pressure Sensor...453
      Lift Cylinder Head Oil Pressure Sensor...453
      Lift Cylinder Bottom Oil Pressure Sensor...453
      Transmission Cutoff Oil Pressure Sensor...454
      Coolant Lever Sensor...455
      Fuel Level Sensor...456
      Air Cleaner Clogging Sensor...457
      Accelerator Pedal Sensor...458
      Water-In-Fuel Sensor...459
      Boom Kickout Proximity Switch...460
      Bucket Positioner Proximity Switch...460
      Lift Arm Potentiometer...461
  20 STANDARD VALUE TABLES...462
    STANDARD VALUE TABLES...463
      Service Value For Engine...463
      Service Values For Chassis...464
    POSTURE AND PERFORMANCE MEASUREMENTS...466
      Machine Posture...471
  30 TESTING AND ADJUSTING...474
    TOOLS...479
      Tools for Testing, Adjusting, and Troubleshooting...479
    ENGINE COMPONENTS...485
      Engine Speed...485
        Measure Engine Speed (Low and High Idle)...485
        Measure Torque Converter Stall Speed...485
        Measure Hydraulic Stall Speed...486
        Measure Torque Converter Stall and Hydraulic Stall (Full Stall) Speed...486
      Exhaust Gas Color...487
        Using Handy Smoke Checker A1...487
        Using Smoke Meter A2...487
      Valve Clearance...489
      Engine Compression...491
      Blow-by Pressure...495
      Engine Oil Pressure...497
      Intake Air (Boost) Pressure...498
      Determining a Defective Cylinder...500
        Procedures...500
        Determining Cylinder Group...500
        Isolating the Defective Cylinder...500
    FUEL SYSTEM...501
      Handling Fuel System Equipment...501
      Releasing Residual Pressure in Fuel System...501
      Measuring Fuel Pressure...502
        Measuring Pressure in Fuel Low-pressure Circuit...502
        Measuring Pressure in Fuel Return Circuit...503
        Measuring Fuel Negative-Pressure Circuit Pressure...504
      Fuel Delivery, Return, and Leak Rate...505
        Measuring Supply Pump Delivery...505
        Measuring Return Rate from Supply Pump...506
        Measuring Leakage from Pressure Limiter...507
        Measuring Return Rate from Injector...508
      Bleeding Air from Fuel Circuit...509
      Testing Leakage in Fuel System...510
      Handling Reduced Cylinder Mode Operation...511
      Handling No-Injection Cranking Operation...511
      Handling Controller Voltage Circuit...511
    EXHAUST SYSTEM AND PIPING...512
      Checking Muffler and Muffler Stack for Looseness and Damage...512
      Checking Muffler Function...512
      Checking Installed Condition of Cylinder Head and Manifolds...512
      Checking Engine Piping for Damage and Looseness...512
    BELTS...513
      Air Conditioner Compressor Belt...513
      Alternator Belt...514
    DIRECTIONAL LEVER...516
      Checking Operating Effort...516
      Checking Stroke...516
    POWER TRAIN OIL PRESSURES...517
      Oil Pressure Measuring Points And Gauges...519
      Measuring Transmission Hydraulic Operating Pressures...520
        Transmission Main Relief Pressure...520
        Torque Converter Relief Pressure (Inlet)...521
        Torque Converter Outlet Pressure...522
        Lockup Clutch Pressure (Lockup Clutch Specification)...523
        F (Forward) Clutch Pressure...524
        R (Reverse) Clutch Pressure...525
        1st Clutch Pressure...526
        2nd Clutch Pressure...527
        3rd Clutch Pressure...528
        4th Clutch Pressure...529
        Lubrication Pressure...530
      Adjusting Power Train Oil Pressures...531
        Transmission Main Relief Valve...531
    TRANSMISSION...532
      Speed Sensor...532
      Flushing Transmission System...533
        Torque Converter, Transmission, and Hydraulic Circuit...533
      Moving the Machine if Transmission Valve Fails...535
    STEERING SYSTEM...539
      Steering Stop Valve...539
        Testing...539
        Adjusting...539
      Steering Wheel...541
        Measuring Play in Steering Wheel...541
        Measuring Operating Effort of Steering Wheel...541
        Measuring Operating Time of Steering Wheel...542
      Steering Oil Pressure...543
        Measuring Steering Relief Pressure...543
        Measuring Steering Pilot Circuit Pressure...544
        Adjusting Steering Relief Pressure...545
        Adjusting Steering Control Circuit Pressure...545
      Bleeding Air from Steering Circuit...546
        Bleeding Air from Steering Pump...546
        Bleeding Air from Steering Cylinder Circuit...546
      Steering Column Lock Lever...547
    HYDRAULIC DRIVE FAN...549
      Measuring Fan Speed...549
      Measuring Fan Drive Oil Pressure...550
      Bleeding Air from Hydraulic Drive Fan Circuit...551
        Bleeding Air From Fan Pump...551
        Bleeding Air from Fan Motor Circuit...552
    WHEEL BRAKE SYSTEM...553
      Measuring Pressing Angle of Brake Pedal...553
      Measuring Brake Performance...554
      Accumulator Charge...555
        Measuring...555
        Adjusting...556
      Measuring Brake Oil Pressure...557
      Testing Wear of Wheel Brake Disc...559
      Bleeding Air from Brake Circuit...560
      Releasing Residual Pressure in Brake Accumulator Circuit...560
    PARKING BRAKE SYSTEM...561
      Testing Parking Brake Performance...561
      Measuring Parking Brake Oil Pressure...563
      Checking Wear of Parking Brake Disc...565
      Releasing Parking Brake Manually...566
    WORK EQUIPMENT SYSTEM...567
      Work Equipment Control Levers...567
        Measuring Operating Effort...567
        Measuring Stroke...567
      PPC Oil Pressure...568
        Measuring PPC Valve Basic Pressure...568
        Measuring PPC Valve Output Pressure...569
        Replacing PPC Relief Valve...570
      Work Equipment Hydraulic Pressure...571
        Measuring Work Equipment Relief Pressure...572
        Measuring Unload Pressure...573
        Measuring Work Equipment LS Differential Pressure...574
        Adjusting Work Equipment Relief Pressure...575
        Adjusting LS Differential Pressure...575
      Bleeding Air from Work Equipment Circuit...576
        From Work Equipment Pump (Piston Pump)...576
        From Hydraulic Cylinder...576
      Releasing Residual Pressure in Work Equipment Circuit...577
        From Circuit Between Hydraulic Cylinders and Control Valve...577
        From ECSS (Travel Damper) Circuit...577
      Work Equipment Positioners...578
        Bucket Positioner...578
        Boom Kickout...579
      Proximity Switch Operation Pilot Lamp...580
    ELECTRICAL SYSTEM TROUBLESHOOTING...581
      Procedure for Testing Diodes...581
        When Using Digital Type Circuit Tester...581
        When Using Analog Type Circuit Tester...582
      Preparation for Troubleshooting Electric System...583
        Machine Monitor...583
        Transmission Controller...584
        Work Equipment Controller...585
        KOMTRAX Terminal...585
        Sensors...586
        Boost Pressure and Temperature Sensor (BOOST PRESS & IMT)...586
        Supply Pump IMV Solenoid (FUEL REGULATOR)...586
        Common Rail Pressure Sensor (FUEL RAIL PRESS)...587
        Engine Coolant Temperature Sensor (COOLANT TEMP)...587
    KOMTRAX TERMINAL SYSTEM...588
      Terminal Installed at Plant Before Shipment...588
      Terminal Retrofitted Machine After Shipment...588
      Starting Operation...588
        Application for the Start of Use...591
      Komtrax Terminal Lamps...593
        Display Contents of 7-segment And Dot For CPU...595
    MACHINE MONITOR SYSTEM...596
      Adjusting Machine Monitor...596
      Adjusting for Replaced, Reassembled, or Added Sensor/Controller...597
      Adjustment for User’s Needs...598
      Special Functions of Machine Monitor (EMMS)...599
        Normal and Special Functions of Machine Monitor...599
      Functions and Flow of Service Mode...600
      Operator Mode...603
        Service Meter/Clock Display Function (1)...603
        Load Meter Function (2) (if equipped)...603
        Odometer Display Function (3)...603
        Maintenance Monitoring Function (4)...604
        Telephone Number Input Function (5)...604
        Language Selection Function (6)...604
        Monitor Brightness Adjustment Function (7)...604
        Time Adjustment Function (8)...605
        Travel Speed/Engine Speed Display Selecting Function (9)...605
        Travel Speed/Engine Speed Display/Non-Display Selecting Function (10)...605
        Action Code Display Function (11)...606
        Failure Code Display Function (12)...606
      Service Mode...608
        Switching to Service Mode and Screen Display (1)...608
        Electrical System Fault History Display Function (ELECTRIC FAULT) (2)...610
        Mechanical System Fault History Display Function (MACHINE FAULT) (3)...612
        Real-Time Monitoring Function (REAL-TIME MONITOR) (4)...613
        Real-Time Monitoring Code Tables...616
        Engine Reduced-Cylinder Function (CYLINDER CUT-OUT) (5)...643
        No-Injection Cranking Function (6)...644
        Adjustment Function (TUNING) (7)...645
        Maintenance Monitoring Function (8)...662
        Operating Information Display Function (OPERATION INFO) (9)...668
        Optional Device Selecting Function (10)...671
        Machine Serial Number Input Function (11)...675
        Model Select Function (12)...675
        Initialize Function (13)...676
    PM-CLINIC INSPECTION TABLE...677
  40 TROUBLESHOOTING...682
    POINTS TO REMEMBER WHEN TROUBLESHOOTING...697
    SEQUENCE OF EVENTS IN TROUBLESHOOTING...699
    PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...700
      Precautions when Handling Electrical Equipment...700
      Handling Electronic Control Unit...705
      Points to Remember when Troubleshooting Electrical Circuits...706
    ELECTRIC WIRE CODE...707
      Classification by Thickness...707
      Classification by Color and Code...707
      How to Read Electric Wire Code...708
        Type, Symbol, and Material...708
        Dimensions...709
    HANDLING HYDRAULIC EQUIPMENT...710
    CHECKS BEFORE TROUBLESHOOTING...712
      Categories and Method of Using Troubleshooting Charts...713
      Troubleshooting Individual Electrical Circuits...714
        Chart Use...716
        Chart Tips...716
      Troubleshooting Individual Hydraulic Circuits...717
    CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...719
      X-Type Connectors...719
      SWP-Type Connectors...721
      M-Type Connectors...723
      S-Type Connectors...725
      MIC-Type Connectors...727
      AMP040-Type Connectors...729
      AMP070-Type Connectors...731
      AMP Connector...733
      L-Type Connector...733
      PA-Type Connector...734
      Bendix (MS) Connector...734
      KES1 (Automobile) Connectors...735
      F-Type Connector...736
      Connectors for Relay (Socket-Type)...737
      HD30 Series Connectors...738
      DT Series Connectors...744
      DTM Series Connectors...746
      DTHD Series Connectors...746
      DTP Series Connectors...747
      DRC26 Series Connectors...748
      DRC12, 16 Series Connectors...750
      AMP Connectors for Pump Controller (CH700)...751
      BOSCH Connectors for Engine...752
      SUMITOMO Connectors for Engine...753
      CANNON Connector for Engine...754
      AMP Connectors for Engine...755
      FRAMATOME Connectors for Engine...756
      PACKARD Connectors for Engine...758
      DT Series Connectors for Engine...759
    T-BRANCH BOX and T-BRANCH ADAPTER TABLE...760
    MODE CHART...765
    INFORMATION CONTAINED IN TESTING PROCEDURES...768
    TROUBLESHOOTING BY FAILURE CODE...770
      Failure Code Table...770
    FUSE BOX AND SLOW-BLOW FUSES...781
      Connection Table...781
        Fuse Box 1...781
        Fuse Box 2...782
        Slow-Blow Fuses...782
    FAILURE CODES...784
      1500L0...784
        TORQFLOW Transmission: Double Meshing...784
      15SAL1...785
        ECMV F Clutch: When Command Current is OFF, Fill Signal is ON...785
      15SALH...787
        ECMV F Clutch: When Command Current is ON, Fill Signal is OFF...787
      15SBL1...789
        ECMV R Clutch: When Command Current is OFF, Fill Signal is ON...789
      15SBLH...791
        ECMV R Clutch: When Command Current is ON, Fill Signal is OFF...791
      15SEL1...793
        ECMV 1st Clutch: When Command Current is OFF, Fill Signal is ON...793
      15SELH...795
        ECMV 1st Clutch: When Command Current is ON, Fill Signal is OFF...795
      15SFL1...797
        ECMV 2nd Clutch: When Command Current is OFF, FIll Signal is ON...797
      15SFLH...799
        ECMV 2nd Clutch: When Command Current is ON, Fill Signal is OFF...799
      15SGL1...801
        ECMV 3rd Clutch: When Command Current is OFF, Fill Signal is ON...801
      15GLH...803
        ECMV 3rd Clutch: When Command Current is ON, Fill Signal is OFF...803
      15SHL1...805
        ECMV 4th Clutch: When Command Current is OFF, Fill Signal is ON...805
      15SHLH...807
        ECMV 4th Clutch: When Command Current is ON, Fill Signal is OFF...807
      2F00MA...809
        Parking Brake: Malfunction...809
      2G43ZG...811
        Rear Accumulator: Low Oil Pressure...811
      44K0L4...813
        Bucket Positioner: ON/OFF Signals Disagree...813
      AA1ANX...817
        Air Cleaner: Clogging...817
      AB00L6...819
        Alternator: Signal Disagrees with Operating State of Engine...819
      AB00MA...821
        Alternator: Malfunction...821
      B@BAZG...823
        Engine: Rotation Derating by Low Engine Oil Pressure...823
      B@BAZK...824
        Engine Oil: Low Level...824
      B@BCNS...825
        Engine Coolant: Overheating...825
      B@BCZK...827
        Engine Coolant: Low Level...827
      B@BEBF...829
        Water in Fuel Error...829
      B@C7NS...831
        Brake Oil: Overheating...831
      b@CENS...833
        Torque Converter Oil: Overheating...833
      B@CENS...835
        Torque Converter Oil: Overheating...835
      B@HANS...837
        Hydraulic Oil: Overheating...837
      CA111...839
        Abnormality in Engine Controller...839
      CA115...840
        Engine Ne or Bkup Speed Sensor Error...840
      CA122...841
        Charge Pressure Sensor High Error...841
      CA123...843
        Charge Pressure Sensor Low Error...843
      CA131...845
        Throttle Sensor High Error...845
      CA132...847
        Throttle Sensor Low Error...847
      CA144...849
        Coolant Temperature Sensor High Error...849
      CA145...851
        Coolant Temperature Sensor Low Error...851
      CA153...853
        Charge Temperature Sensor High Error...853
      CA154...855
        Charge Temperature Sensor Low Error...855
      CA155...857
        Derating of Speed by Abnormally High Charge Temperature...857
      CA187...859
        Sensor Power Supply 2 Low Error...859
      CA221...861
        Atmospheric Pressure Sensor High Error...861
      CA222...863
        Atmospheric Pressure Sensor Low Error...863
      CA227...865
        Sensor Power Supply 2 High Error...865
      CA234...867
        Engine Overspeed...867
      CA238...868
        Ne Speed Sensor Power Supply Error...868
      CA271...869
        IMV/PCV1 Short Circuit...869
      CA272...871
        IMV/PCV1 Disconnection...871
      CA322...873
        Injector #1 Open/Short Error...873
      CA323...875
        Injector #5 Open/Short Error...875
      CA324...877
        Injector #3 Open/Short Error...877
      CA325...879
        Injector #6 Open/Short Error...879
      CA331...881
        Injector #2 Open/Short Error...881
      CA332...883
        Injector #4 Open/Short Error...883
      CA342...885
        Calibration Code Inconsistency...885
      CA351...887
        Injectors Drive Circuit Error...887
      CA352...889
        Sensor Power Supply 1 Low Error...889
      CA386...891
        Sensor Power Supply 1 High Error...891
      CA428...893
        Abnormally High Level in Water Sensor...893
      CA429...895
        Abnormally Low Level in Water Sensor...895
      CA431...897
        Idle Validation Switch Error...897
      CA432...901
        Idle Validation Action Error...901
      CA435...905
        Engine Oil Pressure Switch Error...905
      CA441...907
        Battery Voltage Low Error...907
      CA442...911
        Battery Voltage High Error...911
      CA449...913
        Common Rail Pressure High Error 2...913
      CA451...917
        Common Rail Pressure Sensor High Error...917
      CA452...919
        Common Rail Pressure Sensor Low Error...919
      CA488...921
        Derating of Torque by Abnormally High Charge Temperature...921
      CA553...922
        Common Rail Pressure High Error 1...922
      CA559...923
        Supply Pump Pressure Very Low Error 1...923
      CA689...925
        Engine Ne Speed Sensor Error...925
      CA731...927
        Engine Bkup Speed Sensor Phase Error...927
      CA757...928
        All Continuous Data Lost Error...928
      CA778...931
        Engine Bkup Speed Sensor Error...931
      CA1633...933
        KOMNET Datalink Timeout Error...933
      CA2185...935
        Throttle Sensor Power Supply Voltage High Error...935
      CA2186...937
        Throttle Sensor Power Supply Voltage Low Error...937
      CA2249...939
        Supply Pump Pressure Very Low Error 2...939
      CA2311...941
        Abnormality in IMV Solenoid...941
      CA2555...943
        Intake Heater Relay Disconnection Error...943
      CA2556...945
        Intake Heater Relay Short Circuit Error...945
      D150KA...947
        Emergency Steering Relay: Disconnection...947
      D150KB...949
        Emergency Steering Relay: Short Circuit...949
      D150KY...951
        Emergency Steering Relay: Short Circuit with Power Supply Line...951
      D160KA...953
        Backup Lamp Relay: Disconnection...953
      D160KB...955
        Backup Lamp Relay: Short Circuit...955
      D191KA...957
        Joystick Steering Neutral Safety Relay: Disconnection...957
      D191KB...959
        Joystick Steering Neutral Safety Relay: Short Circuit...959
      D191KY...961
        Joystick Steering Neutral Safety Relay: Short Circuit with Power Supply Line...961
      D192KA...963
        ECSS Solenoid: Disconnection...963
      D192KB...965
        ECSS Solenoid: Short Circuit...965
      D192KY...967
        ECSS Solenoid Relay: Short Circuit with Power Supply Line...967
      D193KA...969
        Joystick Steering Solenoid Cut Relay: Disconnection...969
      D193KB...971
        Joystick Steering Solenoid Cut Relay: Short Circuit...971
      D193KY...973
        Joystick Steering Solenoid Cut Relay: Short Circuit with Power Supply Line...973
      D5ZHKA...975
        Terminal C Signal: Disconnection...975
      D5ZHKB...979
        Terminal C Signal: Short Circuit...979
      D5ZHKZ...983
        Terminal C Signal: Disconnection or Short Circuit...983
      D5ZHL6...987
        Terminal C Signal: Signal Does Not Match Engine Running or Stopped State...987
      DA80L4...991
        Auto-Grease Controller: ON/OFF Signals Disagree...991
      DAF3KK...993
        Machine Monitor: Low Source Voltage (input)...993
      DAF5KP...995
        Machine Monitor: Low Output Voltage...995
      DAFRKR...999
        Machine Monitor: CAN Defective Communication...999
      DAQ0KK...1003
        Transmission Controller: Low Source Voltage...1003
      DAQ0KT...1005
        Transmission Controller: Abnormality in Controller...1005
      DAQ2KK...1007
        Transmission Controller Load Power Supply Line: Low Source Voltage (input)...1007
      DAQ9KQ...1009
        Transmission Controller: Disagreement of Model Selection Signals...1009
      DAQRKR...1011
        CAN Communication with Transmission Controller: Defective Communication...1011
      DAQRMA...1014
        Transmission Controller Option Setting: Malfunction...1014
      DB2RKR...1015
        CAN Communication with Engine Controller: Defective Communication...1015
      DB90KK...1019
        Work Equipment Controller: Low Source Voltage (input)...1019
      DB90KT...1021
        Work Equipment Controller: Abnormality in Controller...1021
      DB92KK...1023
        Work Equipment Controller Load Power Supply Line: Low Source Voltage (input)...1023
      DD95KX...1025
        Work Equipment Controller Power Supply Output: Out-of-Input Signal Range...1025
      DB99KQ...1028
        Work Equipment Controller: Disagreement in Model Selection Signals...1028
      DB9RKR...1029
        CAB Communication with Work Equipment Controller: Defective Communication...1029
      DB9RMA...1032
        Work Equipment Controller Option Setting: Malfunction...1032
      DB9RMC...1033
        CAN Communication: Defective Operation...1033
      DD15LD...1037
        Switch (Panel Switch 1 n): Switch is Pressed for Long Time...1037
      DD16LD...1039
        Switch (Panel Switch 2 ‡): Switch is Pressed for Long Time...1039
      DD17LD...1041
        Switch (Panel Switch 3 <): Switch is Pressed for Long Time...1041
      DD18LD...1043
        Switch (Panel Switch 4 >): Switch is Pressed for Long Time...1043
      DD1ALD...1045
        Remote Positioner Raise/Lower Set Switch (raise): Switch is Pressed for Long Time...1045
      DD1BLD...1047
        Remote Positioner Raise/Lower Set Switch (lower): Switch is Pressed for Long Time...1047
      DD1CLD...1049
        Load Meter Subtotal Switch: Switch is Pressed for Long Time...1049
      DD1FLD...1051
        Load Meter Mode Selector Switch (A/B): Switch is Pressed for Long Time...1051
      DD1GLD...1053
        Load Meter Mode Selector Switch (+/-): Switch is Pressed for Long Time...1053
      DD1HLD...1055
        Load Meter Display Selector Switch: Switch is Pressed for Long Time...1055
      DD1NLD...1057
        Fan Reverse Switch: Switch is Pressed for Long Time...1057
      DD1NL4...1059
        Fan Automatic Reverse Switch: Switch is Pressed for Long Time...1059
      DDB6L4...1061
        Parking Brake Switch (Neutralizer): ON/OFF Signals Disagree...1061
      DDE5MA...1065
        Emergency Steering Drive Switch: Malfunction...1065
      DDK3KA...1067
        Right FNR Switch: Disconnection...1067
      DDK4KA...1070
        Joystick Steering FNR Switch: Disconnection...1070
      DDK5L4...1073
        Joystick Steering Shift UP/DOWN Switch: ON/OFF Signals Disagree...1073
      DDK6KA...1075
        FNR Lever Switch: Disconnection...1075
      DDK6KB...1078
        FNR Lever Switch: Short Circuit...1078
      DDS5KA...1081
        Steering Pressure Switch: Disconnected...1081
      DDS5KB...1083
        Steering Pressure Switch: Grounded...1083
      DDT0L4...1085
        Shift Mode Selector Switch: ON/OFF Signals Disagree...1085
      DDT4LD...1087
        Transmission Cutoff Set Switch: Switch is Pressed for Long Time...1087
      DDW9LD...1089
        Kickdown Switch: Switch is Pressed for Long Time...1089
      DDWLLD...1091
        Hold Switch: Switch is Pressed Down for Long Time...1091
      DDY0LD...1093
        Load Meter Cancel Switch: Switch is Pressed for Long Time...1093
      DF10KA...1095
        Transmission Shift Lever Switch: Disconnected...1095
      DF10KB...1099
        Transmission Shift Lever Switch: Short Circuit...1099
      DGF1KA...1103
        Transmission Oil Temperature Sensor: Disconnected...1103
      DGF1KB...1105
        Transmission Oil Temperature Sensor: Short Circuit...1105
      DGH2KX...1107
        Hydraulic Oil Temperature Sensor: Out-of-Input Signal Range...1107
      DGR2KA...1109
        Rear Brake Oil Temperature Sensor: Disconnected...1109
      DGR2KX...1111
        Rear Brake Oil Pressure Sensor: Out-of-Input Signal Range...1111
      DGT1KX...1113
        Torque Converter Oil Temperature Sensor: Out-of-Input Signal Range...1113
      DHPCKX...1115
        Lift Arm Cylinder Bottom Pressure Sensor: Out-of-Input Signal Range...1115
      DHPDKX...1117
        Lift Arm Cylinder Head Pressure Sensor: Out-of-Input Signal Range...1117
      DHT1KX...1119
        Transmission Cutoff Pressure Sensor: Out-of-Input Signal...1119
      DHT8KA...1121
        Steering Pump Pressure Sensor: Disconnection...1121
      DHT8KB...1123
        Steering Pump Pressure Sensor: Short Circuit...1123
      DK59KA...1125
        Lift Arm EPC Lever Potentiometer (Main): Disconnection...1125
      DK59KY...1128
        Lift Arm EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line...1128
      DK59L8...1131
        Lift Arm EPC Lever Potentiometer (Main): Analog Signals Disagree...1131
      DK5AKA...1135
        Lift Arm EPC Lever Potentiometer (Sub): Disconnection...1135
      DK5AKY...1138
        Lift Arm EPC Lever Potentiometer (Sub): Short Circuit with Power Supply LIne...1138
      DK5BKA...1141
        Bucket EPC Lever Potentiometer (Main): Disconnection...1141
      DK5BKY...1144
        Bucket EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line...1144
      DK5BL8...1147
        Bucket EPC Lever Potentiometer (Main): Analog Signals Disagree...1147
      DK5CKA...1150
        Bucket EPC Lever Potentiometer (Sub): Disconnection...1150
      DK5CKY...1153
        Bucket EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line...1153
      DK5FKA...1156
        Joystick Steering EPC Lever Potentiometer (Main): Disconnection...1156
      DK5FKY...1159
        Joystick Steering EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line...1159
      DK5GKA...1162
        Joystick Steering EPC Lever Potentiometer (Sub): Disconnection...1162
      DK5GKY...1165
        Joystick Steering EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line...1165
      DK5FL8...1168
        Joystick Steering EPC Lever Potentiometer (Main): Analog Signals Disagree...1168
      DKA0KA...1171
        Lift Arm Angle Sensor: Disconnection...1171
      DKA0KY...1175
        Lift Arm Angle Sensor: Short Circuit with Power Supply Line...1175
      DKA0L0...1177
        Lift Arm Angle Sensor: Double Meshing...1177
      DLT3KA...1179
        Transmission Output Shaft Speed Sensor: Disconnection...1179
      DLT3LC...1181
        Transmission Output Shaft Speed Sensor: Out-of-Input Signal Range...1181
      DT20KB...1183
        Transmission Cutoff Indicator Lamp: Short Circuit...1183
      DUM1KB...1185
        Remote Positioner Raise Set Indicator Lamp: Short Circuit...1185
      DUM2KB...1187
        Remote Positioner Lower Set Indicator Lamp: Short Circuit...1187
      DV00KB...1189
        Alarm Buzzer: Short Circuit...1189
      DW4PKA...1191
        Lift Arm Raise EPC Solenoid: Disconnection...1191
      DW4PKB...1193
        Lift Arm Raise EPC Solenoid: Short Circuit...1193
      DW4PKY...1195
        Lift Arm Raise EPC Solenoid: Short Circuit with Power Supply Line...1195
      DW4QKA...1197
        Lift Arm Lower EPC Solenoid: Disconnection...1197
      DW4QKB...1199
        Lift Arm Lower EPC Solenoid: Short Circuit...1199
      DW4QKY...1201
        Lift Arm Lower EPC Solenoid: Short Circuit with Power Supply Line...1201
      DW4RKA...1203
        Bucket Tilt EPC Solenoid: Disconnection...1203
      DW4RKB...1205
        Bucket Tilt EPC Solenoid: Short Circuit...1205
      DW4RKY...1207
        Bucket Tilt EPC Solenoid: Short Circuit with Power Supply Line...1207
      DW4SKA...1209
        Buck Dump EPC Solenoid: Disconnection...1209
      DW4SKB...1211
        Bucket Dump EPC Solenoid: Short Circuit...1211
      DW4SKY...1213
        Bucket Dump EPC Solenoid: Short Circuit with Power Supply Line...1213
      DW7BKA...1215
        Fan Reverse Solenoid: Disconnection...1215
      DW7BKB...1217
        Fan Reverse Solenoid: Short Circuit...1217
      DW7BKY...1219
        Fan Reverse Solenoid: Short Circuit with Power Supply Line...1219
      DWM1KA...1221
        Work Equipment Neutral Lock Solenoid: Disconnection...1221
      DWM1KB...1223
        Work Equipment Neutral Lock Solenoid: Short Circuit...1223
      DWM1KY...1225
        Work Equipment Neutral Lock Solenoid: Short Circuit with Power Supply Line...1225
      DWN6KA...1227
        Lift Arm Raise Magnet Detent Solenoid: Disconnection...1227
      DWN6KB...1229
        Lift Arm Raise Magnet Detent Solenoid: Short Circuit...1229
      DWN6KY...1231
        Lift Arm Raise Magnet Detent Solenoid: Short Circuit with Power Supply Line...1231
      DWN7KA...1233
        Lift Arm Float Magnet Detent Solenoid: Disconnection...1233
      DWN7KB...1235
        Lift Arm Float Magnet Detent Solenoid: Short Circuit...1235
      DWN7KY...1237
        Lift Arm Float Magnet Detent Solenoid: Short Circuit with Power Supply Line...1237
      DWN8KA...1239
        Bucket Tilt Magnet Detent Solenoid: Disconnection...1239
      DWN8KB...1241
        Bucket Tilt Magnet Detent Solenoid: Short Circuit...1241
      DWN8KY...1243
        Bucket Tilt Magnet Detent Solenoid: Shorted with the Power Source...1243
      DX16KA...1245
        Fan Pump EPC Solenoid: Disconnection...1245
      DX16KB...1247
        Fan Pump EPC Solenoid: Short Circuit...1247
      DX16KY...1249
        Fan Pump EPC Solenoid: Short Circuit with Power Supply Line...1249
      DXH1KA...1251
        Lockup ECMV Solenoid: Disconnection...1251
      DXH1KB...1253
        Lockup ECMV Solenoid: Short Circuit...1253
      DXH1KY...1255
        Lockup ECMV Solenoid: Short Circuit with Power Supply Line...1255
      DXH4KA...1257
        1st Clutch ECMV Solenoid: Disconnection...1257
      DXH4KB...1259
        1st Clutch ECMV Solenoid: Short Circuit...1259
      DXH4KY...1261
        1st Clutch ECMV Solenoid: Short Circuit with Power Supply Line...1261
      DXH5KA...1263
        2nd Clutch ECMV Solenoid: Disconnection...1263
      DXH5KB...1265
        2nd Clutch ECMV Solenoid: Short Circuit...1265
      DXH5KY...1267
        2nd Clutch ECMV Solenoid: Short Circuit with Power Supply Line...1267
      DXH6KA...1269
        3rd Clutch ECMV Solenoid: Disconnection...1269
      DXH6KB...1271
        3rd Clutch ECMV Solenoid: Short Circuit...1271
      DXH6KY...1273
        3rd Clutch ECMV Solenoid: Short Circuit with Power Supply Line...1273
      DXH7KA...1275
        R Clutch ECMV Solenoid: Disconnection...1275
      DXH7KB...1277
        R Clutch ECMV Solenoid: Short Circuit...1277
      DXH7KY...1279
        R Clutch ECMV Solenoid: Short Circuit with Power Supply Line...1279
      DXH8KA...1281
        F Clutch ECMV Solenoid: Disconnection...1281
      DXH8KB...1283
        F Clutch ECMV Solenoid: Short Circuit...1283
      DXH8KY...1285
        F Clutch ECMV Solenoid: Short Circuit with Power Supply Line...1285
      DXHHKA...1287
        4th Clutch ECMV Solenoid: Disconnection...1287
      DXHHKB...1289
        4th Clutch ECMV Solenoid: Short Circuit...1289
      DXHHKY...1291
        4th Clutch ECMV Solenoid: Short Circuit with Power Supply Line...1291
      DXHLKA...1293
        Joystick Steering Right EPC Solenoid: Disconnection...1293
      DXHLKB...1295
        Joystick Steering Right EPC Solenoid: Short Circuit...1295
      DXHLKY...1297
        Joystick Steering Right EPC Solenoid: Short Circuit with Power Supply Line...1297
      DXHMKA...1299
        Joystick Steering Left EPC Solenoid: Disconnection...1299
      DXHMKB...1301
        Joystick Steering Left EPC Solenoid: Short Circuit...1301
      DXHMKY...1303
        Joystick Steering Left EPC Solenoid: Short Circuit with Power Supply Line...1303
      DY30MA...1305
        Motor-Driven Emergency Steering Pump Failure (during Operation of machine)...1305
      DY30MC...1308
        Motor-Driven Emergency Steering Pump Failure (Malfunction in Manual Mode)...1308
    TROUBLESHOOTING: E-MODE...1311
      Troubleshooting Electrical System...1311
        Information in Troubleshooting Table...1311
      E-1...1313
        Engine Does Not Start...1313
      E-2...1319
        Wiper Does Not Operate...1319
      E-3...1323
        Windshield Washer Does Not Operate...1323
      E-4...1327
        Headlamp, Clearance Lamp, Tail Lamp, and License Lamp Do Not Light Up or Go Off...1327
      E-5...1335
        Working Lamp Does Not Light Up or Go Off...1335
      E-6...1341
        Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off...1341
      E-7...1347
        Brake Lamp Does Not Light or It Keeps Lighting Up...1347
      E-8...1350
        Backup Lamp Does Not Light or It Keeps Lighting Up...1350
      E-9...1353
        Backup Buzzer Does Not Sound or It Keeps Sounding...1353
      E-10...1356
        Horn Does Not Sound or It Keeps Sounding...1356
      E-11...1359
        Alarm Buzzer Does Not Sound or It Keeps Sounding...1359
      E-12...1361
        Air Conditioner Does Not Operate or Stop...1361
      E-13...1365
        KOMTRAX System Does Not Work Properly...1365
          Indicator Lamps of KOMTRAX Terminal...1367
      E-14...1369
        When Kickdown Switch is Turned On, Kickdown Operation Does Not Start...1369
      E-15...1371
        When Hold Switch is Pressed, Holding Operation Does Not Start...1371
      E-16...1373
        Transmission Kept in Neutral or Brake Drags when Directional Lever is Operated While Parking Brake is Applied...1373
      E-17...1375
        Transmission Cutoff Mode Cannot Be Set or Reset...1375
      E-18...1377
        Transmission Cutoff Set Cannot be Reset...1377
      E-19...1379
        FNR Switch Mode Cannot Be Set or Reset...1379
      E-20...1381
        Fan Reverse Function Cannot Be Used or Reset...1381
      E-21...1383
        Discharge from Loader Pump Does Not Rise from Minimum Level...1383
      E-22...1385
        ECSS Function Cannot Be Used or Reset...1385
      E-23...1387
        When Parking Brake is Turned On, Parking Brake Indicator Lamp Does Not Light Up...1387
      E-24...1391
        When Emergency Brake Operates, Brake Oil Pressure Caution Lamp Does Not Operate...1391
      E-25...1393
        Air Cleaner Clogging Indicator Lamp Does Not Light Up...1393
      E-26...1395
        Radiator Coolant Level Caution Lamp Does Not Light Up...1395
      E-27...1397
        Hydraulic Oil Temperature Gauge Does Not Rise and Hydraulic Oil Temperature Caution Lamp Does Not Light Up...1397
      E-28...1399
        Torque Converter Oil Temperature Gauge Does Not Rise and Torque Converter Oil Temperature Caution Lamp Does Not Light Up...1399
      E-29...1401
        Steering Oil Pressure Caution Lamp Does Not Light Up...1401
      E-30...1403
        Abnormality in Switch (n) (Panel Switch 1) Input...1403
      E-31...1405
        Abnormality in Switch (‡) (Panel Switch 2) Input...1405
      E-32...1407
        Abnormality in Switch (<) (Panel Switch 3) Input...1407
      E-33...1409
        Abnormality in Switch (>) (Panel Switch 4) Input...1409
    TROUBLESHOOTING: H-MODE...1411
      Troubleshooting Hydraulic and Mechanical Systems...1411
        Using Troubleshooting Chart...1411
      Failure Codes and Causes Table...1413
      H-1...1417
        Machine Does Not Start...1417
      H-2...1419
        Torque Converter Lockup is Not Switched OFF (Engine Stalls)...1419
      H-3...1420
        Torque Converter Lockup is Not Switched ON...1420
      H-4...1421
        Travel Speed is Slow, Thrusting Force is Weak, Uphill Traveling Power is Weak, Gear is Not Shifted...1421
      H-5...1425
        Large Shocks When Starting and Shifting Gears...1425
      H-6...1429
        Large Time Lag When Starting and Shifting Gear...1429
      H-7...1433
        Torque Converter Oil Temperature is High...1433
      H-8...1434
        Steering Does Not Turn...1434
      H-9...1435
        Steering Does Not Turn (Joystick Steering, if equipped)...1435
      H-10...1436
        Steering Response is Poor...1436
      H-11...1437
        Steering, Turning Response is Poor (Joystick Steering, if Equipped)...1437
      H-12...1438
        Steering is Heavy...1438
      H-13...1439
        When Machine Turns, It Shakes or Jerks...1439
      H-14...1440
        When Machine Turns, It Shakes or Jerks (Joystick Steering, if Equipped)...1440
      H-15...1441
        Wheel Brake Does Not Work or Does Not Work Well...1441
      H-16...1442
        Wheel Brake is Not Released or It Drags...1442
      H-17...1443
        Parking Brake Does Not Work or Does Not Work Well...1443
      H-18...1444
        Parking Brake is Not Released or It Drags...1444
      H-19...1445
        Lift Arm Does Not Rise...1445
      H-20...1446
        Lift Arm Speed is Low or Rising Force is Insufficient...1446
      H-21...1447
        When Rising, Lift Arm Starts to Move Slowly at a Specific Height...1447
      H-22...1447
        Lift Arm Cylinder Cannot Hold Down Bucket (Bucket Floats)...1447
      H-23...1447
        Hydraulic Drifts of the Lift Arm Are Large...1447
      H-24...1448
        Lift Arm Wobbles During Operation...1448
      H-25...1449
        Bucket Does Not Tilt Back...1449
      H-26...1450
        Bucket Speed is Low or Tilting-Back Force Is Insufficient...1450
      H-27...1451
        Bucket Starts to Operate Slowly in the Midst of Tilting Back...1451
      H-28...1451
        Bucket Cylinder Cannot Hold Down the Bucket...1451
      H-29...1451
        Hydraulic Drifts of the Bucket Are Large...1451
      H-30...1452
        Bucket Wobbles During Travel with Load...1452
      H-31...1453
        Lift Arm and Bucket Control Levers Do Not Move Smoothly and Are Heavy...1453
      H-32...1454
        During Operation of Machine, Engine Speed Drops Remarkably or Engine Stalls...1454
      H-33...1454
        Large Shocks When Work Equipment Starts and Stops...1454
      H-34...1454
        When Work Equipment Circuit is Relieved Singly, Other Work Equipment Moves...1454
      H-35...1455
        ECSS Does Not Operate; Pitching and Bouncing Occur...1455
  50 DISASSEMBLY AND ASSEMBLY...1456
    HOW TO READ THIS MANUAL...1460
      Removal and Installation of Assemblies...1460
      Disassembly and Assembly of Assemblies...1462
    COATING MATERIALS LIST...1464
    SPECIAL TOOLS LIST...1467
    SKETCHES OF SPECIAL TOOLS...1470
    CONNECTOR REPAIR PROCEDURES...1476
      Stripping Insulation...1476
      Wire Inspection...1476
      Contact Terminal Removal (HD30 Type)...1477
      Crimping Contact Terminal (HD30 Type)...1478
      Insertion Of Contact Terminal (HD30 Type)...1479
      Contact Terminal Removal (DT Type)...1480
      Crimping Contact Terminal (DT Type)...1481
      Insertion Of Contact Terminal (DT Type)...1482
    ENGINE AND COOLING SYSTEM...1483
      Alternator...1483
      Crankshaft...1483
      Camshaft...1483
      Engine Front Seal...1483
      Engine Oil Cooler...1483
      Engine Rear Seal...1483
      Starting Motor...1483
      Thermostat...1483
      Turbocharger...1483
      Water Pump...1483
      Cylinder Head...1484
        Removal...1484
        Installation...1490
      Engine Hood...1497
        Removal...1497
        Installation...1499
      Radiator...1500
        Removal...1500
        Installation...1501
      Air Aftercooler...1502
        Removal...1502
        Installation...1503
      Hydraulic Oil Cooler...1504
        Removal...1504
        Installation...1505
      Engine...1506
        Removal...1506
        Installation...1511
      Cooling Fan and Fan Motor...1513
        Removal...1513
        Installation...1516
    FUEL SUPPLY SYSTEM...1517
      Fuel Supply Pump...1517
        Removal...1517
        Installation...1518
      Fuel Injector...1519
        Removal...1519
        Installation...1522
      Fuel Tank...1527
        Removal...1527
        Installation...1529
    POWER TRAIN...1530
      Torque Converter and Transmission Assembly...1530
        Removal...1530
        Installation...1537
      Torque Converter (Standard Specification)...1538
        Disassembly...1538
        Assembly...1541
      Torque Converter (Lockup Specification)...1544
        Disassembly...1544
        Assembly...1547
      Transmission...1552
        Disassembly...1552
        Assembly...1562
      Clutch Pack...1573
        Forward and Reverse Clutch Pack: Disassembly...1573
        1st and 4th Clutch Pack: Disassembly...1577
        2nd and 3rd Gear Clutch Pack: Disassembly...1580
        Forward and Reverse Clutch Pack: Assembly...1586
        1st and 4th Clutch Pack: Assembly...1590
        2nd and 3rd Clutch Pack: Assembly...1594
      Parking Brake...1599
        Disassembly...1599
        Assembly...1604
      Front Axle...1611
        Removal...1611
        Installation...1612
      Rear Axle...1613
        Removal...1613
        Installation...1616
      Axle Housing...1618
        Disassembly...1618
        Assembly...1623
      Differential Assembly...1630
        Disassembly...1630
        Assembly...1639
    STEERING SYSTEM...1655
      Steering Valve Assembly...1655
        Removal...1655
        Installation...1657
    BRAKING SYSTEM...1658
      Parking Brake Discs and Plates...1658
        Removal...1658
        Installation...1660
    UNDERCARRAGE AND FRAME...1661
      Center Hinge Pin...1661
        Removal...1661
        Installation...1666
      Counterweight...1671
        Removal...1671
        Installation...1673
    HYDRAULIC SYSTEM...1674
      Work Equipment Control Valve...1674
        Removal...1674
        Installation...1676
      Power Train Pump and Work Equipment Pump Assembly...1677
        Removal...1677
        Installation...1677
      Steering Pump And Cooling Fan Pump Assembly...1678
        Removal...1678
        Installation...1679
      Hydraulic Tank...1680
        Removal...1680
        Installation...1683
    WORK EQUIPMENT...1684
      Work Equipment Assembly...1684
        Removal...1684
        Installation...1687
      Hydraulic Cylinder...1689
        Disassembly...1689
        Assembly...1693
    CAB AND ATTACHMENTS...1698
      Cab and Floor Frame...1698
        Removal...1698
        Installation...1701
      Cab Glass (Stuck Glass)...1702
        Removal...1702
        Installation...1703
      Operator Seat Assembly (Standard Specification) (ISRING HAUSEN)...1711
        Disassembly...1711
        Assembly...1718
      Operator Seat Assembly (GRAMMER)...1723
        Upper Seat...1723
        Suspension...1731
    AIR CONDITIONER UNIT ASSEMBLY...1759
      Removal...1759
      Installation...1763
    ELECTRICAL SYSTEM...1764
      Engine Controller Assembly...1764
        Removal...1764
        Installation...1764
  90 DIAGRAMS AND SCHEMATICS...1766
    AUTOMATIC GREASING...1768
      Auto-Grease Circuit Diagram...1768
    HYDRAULIC SYSTEM...1769
      Power Train Hydraulic Circuit Diagram...1769
        Without Lockup Clutch...1769
        With Lockup Clutch...1769
      Hydraulic Circuit Diagram...1770
    ELECTRICAL SYSTEM...1771
      Machine Monitor System Circuit Diagram...1771
      Transmission Controller System Circuit Diagram...1772
      Work Equipment Controller System Circuit Diagram...1773
      Work Equipment Controller System Electrical Circuit Diagram...1774
      Electrical Circuit Diagram (1/14)...1775
      Electrical Circuit Diagram (2/14)...1776
      Electrical Circuit Diagram (3/14)...1777
      Electrical Circuit Diagram (4/14)...1778
      Electrical Circuit Diagram (5/14)...1779
      Electrical Circuit Diagram (6/14)...1780
      Electrical Circuit Diagram (7/14)...1781
      Electrical Circuit Diagram (8/14)...1782
      Electrical Circuit Diagram (9/14)...1783
      Electrical Circuit Diagram (10/14)...1784
      Electrical Circuit Diagram (11/14)...1785
      Electrical Circuit Diagram (12/14)...1786
      Electrical Circuit Diagram (13/14)...1787
      Electrical Circuit Diagram (14/14)...1788
      Connector List and Stereogram...1789
        Chassis...1789
        Engine and Transmission...1790
        Operator’s Compartment...1791
CEBM017403 - Wheel Loader WA380-6 Shop Manual...1792
  CEBM017403 - WA380-6 sn A53001 and UP...0
    CONTENTS...1793
    REVISED PAGES...1794
    SAFETY...1808
      Safety Notice...1808
        IMPORTANT SAFETY NOTICE...1808
        General Precautions...1808
        Preparations for Work...1809
        Precautions During Work...1809
    GENERAL...1810
    HOW TO READ THE SHOP MANUAL...1811
      Volumes...1811
      Distribution and Updating...1811
      Filing Method...1811
      Revised Edition Mark...1811
      Revisions...1811
      Symbols...1811
    HOISTING INSTRUCTIONS...1812
      Hoisting...1812
      Making Signs...1812
      Precautions...1812
        Precautions for Sling Work...1812
        Precautions for Using Mobile Crane...1813
        Precautions for Using Overhead Hoist Crane...1813
      Selecting Wire Ropes...1814
    AIR CONDITIONER CIRCUITS...1815
      Precautions for Handling Hoses and Tubes...1815
        Disconnecting Hoses and Tubes...1815
        Connecting Hoses and Tubes...1815
    MAINTENANCE STANDARD TERMS...1816
      Handling Connectors Used for Engines...1818
        Slide Lock Type...1818
        Pull Lock Type...1819
        Push Lock Type...1819
        Turn-housing Type (Round Green Connector)...1821
    PRECAUTIONS FOR OPERATIONS...1822
      Precautions when Carrying Out Removal Work...1822
      Precautions when Carrying Out Installation Work...1823
      Precautions when Completing the Operation...1824
    PUSH-PULL COUPLER...1825
      Type 1...1825
        Disconnection...1825
        Connection...1825
      Type 2...1826
        Disconnection...1826
        Connection...1826
      Type 3...1827
        Disconnection...1827
        Connection...1827
    COATING MATERIALS...1828
    STANDARD TIGHTENING TORQUE...1830
      Standard Tightening Tables...1830
        For Bolts and Nuts...1830
        For Split Flange Bolts...1831
        For O-Ring Boss Piping Joints...1831
        For O-Ring Boss Plugs...1832
        For Hoses (Taper-Seal Type and Face-Seal Type)...1832
        For Face Seal Joints...1833
        For 102, 107, and 114 Engine Series (Bolts and Nuts)...1833
        For 102, 107, and 114 Engine Series (Eye Joints)...1833
        For 102, 107, and 114 Engine Series (Taper Screws)...1834
    CONVERSION TABLES...1835
      Method of Using the Conversion Table...1835
  01 GENERAL...1842
    SPECIFICATIONS...1844
      Dimension Drawing...1844
      Specification Tables...1846
    WEIGHT TABLE...1851
    FUEL, COOLANT, AND LUBRICANTS...1853
  10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD...1856
    ENGINE AND COOLING SYSTEM...1861
      Engine and Transmission Mounting...1861
      Cooling System...1863
      Cooling Fan Pump...1865
      Servo Valve...1870
      Cooling Fan Motor System...1873
      Hydraulic Motor...1876
      Suction Valve...1879
      Reversible Valve...1877
      Safety Valve...1878
    POWER TRAIN SYSTEM...1880
      Drive Line Components...1880
      System Diagram...1881
      Drive Shaft System...1883
      Power Train Piping System...1884
      Torque Converter...1885
        Without Lockup Clutch...1885
        Power Transmitting Route...1887
        Oil Flow...1887
        With Lockup Clutch...1888
      Torque Flow...1891
        When Lockup Clutch Is Disengaged...1891
        When Lockup Clutch Is Engaged...1891
        Oil Flow...1892
      Transmission...1893
        With Lockup Clutch...1893
      Forward and Reverse Clutches...1903
        Without Lockup Clutch...1903
        With Lockup Clutch...1904
        1st and 4th Clutches...1905
        2nd and 3rd Clutches...1906
        Operation of Clutch Pack...1907
      Transmission Torque Flow Route...1909
        Forward 1st Gear Speed...1909
        Forward 2nd Gear Speed...1911
        Forward 3rd Gear Speed...1913
        Forward 4th Gear Speed...1915
        Reverse 1st Gear Speed...1917
      Flow Control Valve...1919
        Valve Assembly...1921
      ECMV System...1923
        For R, 1st, and 2nd Clutches...1923
        For F, 3rd, 4th, and Lockup Clutches...1925
        ECMV For Gear Speed Clutch...1927
        ECMV for Lockup Clutch...1930
      Main and Torque Converter Relief Valve System...1933
        Outline...1935
        Operation...1935
    DRIVE AXLE SYSTEM...1936
      Front Axle Assembly...1936
      Rear Axle Assembly...1937
      Front Differential...1939
      Rear Differential...1941
      Limited Slip Differential...1944
      Front Axle Carrier...1945
      Rear Axle Carrier...1947
      Final Drive...1951
    STEERING SYSTEM...1953
      Steering Piping Diagram...1953
      Steering Column...1954
      Steering Pump...1955
        Pump Unit...1957
        Servo Valve...1962
        LS Valve...1965
        PC Valve...1965
      Steering Valve...1969
        Operation of Flow Amplifier...1973
        Operation of Flow Control Spool...1975
        Operation of Steering Valve...1977
        Steering Relief Valve...1980
        Overload Relief Valve...1981
        Relief Valve...1982
      Orbitrol Valve...1983
      Stop Valve...1987
      Steering Relief Valve...1988
      Steering Cylinder...1989
      Emergency Steering Motor...1991
      Emergency Steering Pump (If Equipped)...1992
      Joystick Steering Lever Linkage...1993
      Steering Electric Lever...1994
      Joystick EPC Valve...1995
      Multi-Function Lever and Joystick Lever (Modification)...1996
    SERVICE BRAKING SYSTEM...1998
      Brake Piping Diagram...1998
      Charge Valve...1999
      Brake Valve...2007
      Accumulator (for Brakes)...2012
      Front Brake...2013
      Rear Brake...2015
    PARKING BRAKE SYSTEM...2017
      Brake Control...2017
      Parking Brake Unit...2019
      Parking Brake Solenoid Valve...2021
      Emergency Parking Brake Release Valve...2023
    UNDERCARRIAGE AND FRAME...2024
      Axle Mounting and Center Hinge Pin...2024
      Tires...2029
    HYDRAULIC SYSTEM...2031
      Piping Diagram...2031
      Work Equipment Control Lever System...2034
      Multi-Function Mono-Lever Type...2035
      Hydraulic Tank...2037
        Tank Vent System...2038
      Power Train Pump...2039
      Work Equipment Pump...2041
        Pump Unit...2043
        Servo Valve...2045
        LS Valve...2051
        PC valve...2052
      Work Equipment Control Valve...2055
        4-Spool Valve...2057
      CLSS...2073
        Outline of CLSS...2073
        Basic Principle...2074
        Pressure Compensation Control...2075
      Function and Operation of Each Valve...2076
        Unload Valve...2077
        Work Equipment Valve (Supply of LS Pressure)...2080
        LS Bypass Plug...2082
        Pressure Compensation Valve...2083
        Lift Arm Regeneration Circuit...2087
        Variable Lift Check Valve...2089
        ECSS Control Valve...2090
        Accumulator Charge Valve...2093
        PPC Valve...2097
        Stabilizer Valve...2102
        Work Equipment PPC Cutoff Solenoid Valve...2107
      Accumulator (for PPC Circuit)...2109
      Accumulator (for ECSS)...2110
    WORK EQUIPMENT...2111
      Work Equipment Linkage...2111
      Bucket...2113
      Bucket Positioner and Boom Kickout...2115
        Bucket Positioner...2116
        Boom Kick-out...2116
        Proximity Switch...2117
      Work Equipment Cylinders...2123
        Lift Cylinder...2123
        Bucket Cylinder...2123
    CAB ENVIRONMENT...2124
      ROPS Cab...2124
      Air Conditioner...2125
        Air Conditioner Piping Diagram...2125
        Refrigerant Circuit Diagram...2127
        Air Conditioner Unit...2128
        Blower and Intake Unit...2131
        Refrigerant Compressor...2132
        Condenser...2133
        Receiver...2134
        Air Conditioner Panel...2135
    ELECTRICAL SYSTEM...2139
      Machine Monitor System...2139
        System Circuit Diagram...2141
        Machine Monitor...2142
        Items Displayed on Monitor...2143
      Machine Monitor Operation Switches...2152
        Setting Machine Monitor...2153
        Troubleshooting Function...2153
        Character Display Function...2154
        Operator Mode Functions...2155
        Service Mode Functions...2158
        Input and Output Signals...2163
      Transmission Controller System...2171
        Gearshifting Control Function...2171
        Cooling Fan Control Function...2190
        Work Equipment Pump Swash Plate Control Function...2195
        Transmission Cutoff Function...2197
        ECSS Function...2199
        Electric Emergency Steering Function...2201
        Directional Selector Switch Control Function...2203
        Multi-Function Mono Lever Function...2205
        Joystick Steering Function...2207
        System Circuit Diagram...2210
        Transmission Controller...2211
      Work Equipment Controller System...2213
        System Circuit Diagram...2215
        Work Equipment Controller...2217
    ELECTRONIC TRANSMISSION CONTROL...2219
      Combination Switch...2221
    KICKDOWN AND HOLD SWITCH...2223
      Load Meter Cancel Switch and Load Meter Subtotal Switch...2223
    MULTI-FUNCTION KNOB...2224
      Modification of Multi-Function Lever...2225
    JOYSTICK STEERING KNOB...2227
    KOMTRAX TERMINAL SYSTEM...2228
      KOMTRAX Terminal...2229
      Input and Output Signals...2230
    ENGINE STARTING CIRCUIT...2231
    ENGINE STOPPING CIRCUIT...2233
    PREHEATING CIRCUIT...2234
    ENGINE POWER MODE SELECTOR CIRCUIT...2235
    ENGINE OUTPUT DERATING FUNCTION...2236
    AUTOMATIC WARM-UP FUNCTION...2236
    PARKING BRAKE CIRCUIT...2237
    SENSORS...2239
      Speed Sensor...2239
      Torque Converter Oil Temperature Sensor...2240
      Hydraulic Oil Temperature Sensor...2240
      Transmission Oil Temperature Sensor...2240
      Brake Oil Temperature Sensor...2240
      Work Equipment Pump Oil Pressure Sensor...2241
      Steering Pump Oil Pressure Sensor...2241
      Lift Cylinder Head Oil Pressure Sensor...2241
      Lift Cylinder Bottom Oil Pressure Sensor...2241
      Transmission Cutoff Oil Pressure Sensor...2242
      Coolant Lever Sensor...2243
      Fuel Level Sensor...2244
      Air Cleaner Clogging Sensor...2245
      Accelerator Pedal Sensor...2246
      Water-In-Fuel Sensor...2247
      Boom Kickout Proximity Switch...2248
      Bucket Positioner Proximity Switch...2248
      Lift Arm Potentiometer...2249
  20 STANDARD VALUE TABLES...2250
    STANDARD VALUE TABLES...2251
      Service Value For Engine...2251
      Service Values For Chassis...2252
    POSTURE AND PERFORMANCE MEASUREMENTS...2254
      Machine Posture...2259
  30 TESTING AND ADJUSTING...2262
    TOOLS...2267
      Tools for Testing, Adjusting, and Troubleshooting...2267
    ENGINE COMPONENTS...2273
      Engine Speed...2273
        Measure Engine Speed (Low and High Idle)...2273
        Measure Torque Converter Stall Speed...2273
        Measure Hydraulic Stall Speed...2274
        Measure Torque Converter Stall and Hydraulic Stall (Full Stall) Speed...2274
      Exhaust Gas Color...2275
        Using Handy Smoke Checker A1...2275
        Using Smoke Meter A2...2275
      Valve Clearance...2277
      Engine Compression...2279
      Blow-by Pressure...2283
      Engine Oil Pressure...2285
      Intake Air (Boost) Pressure...2286
      Determining a Defective Cylinder...2288
        Procedures...2288
        Determining Cylinder Group...2288
        Isolating the Defective Cylinder...2288
    FUEL SYSTEM...2289
      Handling Fuel System Equipment...2289
      Releasing Residual Pressure in Fuel System...2289
      Measuring Fuel Pressure...2290
        Measuring Pressure in Fuel Low-pressure Circuit...2290
        Measuring Pressure in Fuel Return Circuit...2291
        Measuring Fuel Negative-Pressure Circuit Pressure...2292
      Fuel Delivery, Return, and Leak Rate...2293
        Measuring Supply Pump Delivery...2293
        Measuring Return Rate from Supply Pump...2294
        Measuring Leakage from Pressure Limiter...2295
        Measuring Return Rate from Injector...2296
      Bleeding Air from Fuel Circuit...2297
      Testing Leakage in Fuel System...2298
      Handling Reduced Cylinder Mode Operation...2299
      Handling No-Injection Cranking Operation...2299
      Handling Controller Voltage Circuit...2299
    EXHAUST SYSTEM AND PIPING...2300
      Checking Muffler and Muffler Stack for Looseness and Damage...2300
      Checking Muffler Function...2300
      Checking Installed Condition of Cylinder Head and Manifolds...2300
      Checking Engine Piping for Damage and Looseness...2300
    BELTS...2301
      Air Conditioner Compressor Belt...2301
      Alternator Belt...2302
    DIRECTIONAL LEVER...2304
      Checking Operating Effort...2304
      Checking Stroke...2304
    POWER TRAIN OIL PRESSURES...2305
      Oil Pressure Measuring Points And Gauges...2307
      Measuring Transmission Hydraulic Operating Pressures...2308
        Transmission Main Relief Pressure...2308
        Torque Converter Relief Pressure (Inlet)...2309
        Torque Converter Outlet Pressure...2310
        Lockup Clutch Pressure (Lockup Clutch Specification)...2311
        F (Forward) Clutch Pressure...2312
        R (Reverse) Clutch Pressure...2313
        1st Clutch Pressure...2314
        2nd Clutch Pressure...2315
        3rd Clutch Pressure...2316
        4th Clutch Pressure...2317
        Lubrication Pressure...2318
      Adjusting Power Train Oil Pressures...2319
        Transmission Main Relief Valve...2319
    TRANSMISSION...2320
      Speed Sensor...2320
      Flushing Transmission System...2321
        Torque Converter, Transmission, and Hydraulic Circuit...2321
      Moving the Machine if Transmission Valve Fails...2323
    STEERING SYSTEM...2327
      Steering Stop Valve...2327
        Testing...2327
        Adjusting...2327
      Steering Wheel...2329
        Measuring Play in Steering Wheel...2329
        Measuring Operating Effort of Steering Wheel...2329
        Measuring Operating Time of Steering Wheel...2330
      Steering Oil Pressure...2331
        Measuring Steering Relief Pressure...2331
        Measuring Steering Pilot Circuit Pressure...2332
        Adjusting Steering Relief Pressure...2333
        Adjusting Steering Control Circuit Pressure...2333
      Bleeding Air from Steering Circuit...2334
        Bleeding Air from Steering Pump...2334
        Bleeding Air from Steering Cylinder Circuit...2334
      Steering Column Lock Lever...2335
    HYDRAULIC DRIVE FAN...2337
      Measuring Fan Speed...2337
      Measuring Fan Drive Oil Pressure...2338
      Bleeding Air from Hydraulic Drive Fan Circuit...2339
        Bleeding Air From Fan Pump...2339
        Bleeding Air from Fan Motor Circuit...2340
    WHEEL BRAKE SYSTEM...2341
      Measuring Pressing Angle of Brake Pedal...2341
      Measuring Brake Performance...2342
      Accumulator Charge...2343
        Measuring...2343
        Adjusting...2344
      Measuring Brake Oil Pressure...2345
      Testing Wear of Wheel Brake Disc...2347
      Bleeding Air from Brake Circuit...2348
      Releasing Residual Pressure in Brake Accumulator Circuit...2348
    PARKING BRAKE SYSTEM...2349
      Testing Parking Brake Performance...2349
      Measuring Parking Brake Oil Pressure...2351
      Checking Wear of Parking Brake Disc...2353
      Releasing Parking Brake Manually...2354
    WORK EQUIPMENT SYSTEM...2355
      Work Equipment Control Levers...2355
        Measuring Operating Effort...2355
        Measuring Stroke...2355
      PPC Oil Pressure...2356
        Measuring PPC Valve Basic Pressure...2356
        Measuring PPC Valve Output Pressure...2357
        Replacing PPC Relief Valve...2358
      Work Equipment Hydraulic Pressure...2359
        Measuring Work Equipment Relief Pressure...2360
        Measuring Unload Pressure...2361
        Measuring Work Equipment LS Differential Pressure...2362
        Adjusting Work Equipment Relief Pressure...2363
        Adjusting LS Differential Pressure...2363
      Bleeding Air from Work Equipment Circuit...2364
        From Work Equipment Pump (Piston Pump)...2364
        From Hydraulic Cylinder...2364
      Releasing Residual Pressure in Work Equipment Circuit...2365
        From Circuit Between Hydraulic Cylinders and Control Valve...2365
        From ECSS (Travel Damper) Circuit...2365
      Work Equipment Positioners...2366
        Bucket Positioner...2366
        Boom Kickout...2367
      Proximity Switch Operation Pilot Lamp...2368
    ELECTRICAL SYSTEM TROUBLESHOOTING...2369
      Procedure for Testing Diodes...2369
        When Using Digital Type Circuit Tester...2369
        When Using Analog Type Circuit Tester...2370
      Preparation for Troubleshooting Electric System...2371
        Machine Monitor...2371
        Transmission Controller...2372
        Work Equipment Controller...2373
        KOMTRAX Terminal...2373
        Sensors...2374
        Boost Pressure and Temperature Sensor (BOOST PRESS & IMT)...2374
        Supply Pump IMV Solenoid (FUEL REGULATOR)...2374
        Common Rail Pressure Sensor (FUEL RAIL PRESS)...2375
        Engine Coolant Temperature Sensor (COOLANT TEMP)...2375
    KOMTRAX TERMINAL SYSTEM...2376
      Terminal Installed at Plant Before Shipment...2376
      Terminal Retrofitted Machine After Shipment...2376
      Starting Operation...2376
        Application for the Start of Use...2379
      Komtrax Terminal Lamps...2381
        Display Contents of 7-segment And Dot For CPU...2383
    MACHINE MONITOR SYSTEM...2384
      Adjusting Machine Monitor...2384
      Adjusting for Replaced, Reassembled, or Added Sensor/Controller...2385
      Adjustment for User’s Needs...2386
      Special Functions of Machine Monitor (EMMS)...2387
        Normal and Special Functions of Machine Monitor...2387
      Functions and Flow of Service Mode...2388
      Operator Mode...2391
        Service Meter/Clock Display Function (1)...2391
        Load Meter Function (2) (if equipped)...2391
        Odometer Display Function (3)...2391
        Maintenance Monitoring Function (4)...2392
        Telephone Number Input Function (5)...2392
        Language Selection Function (6)...2392
        Monitor Brightness Adjustment Function (7)...2392
        Time Adjustment Function (8)...2393
        Travel Speed/Engine Speed Display Selecting Function (9)...2393
        Travel Speed/Engine Speed Display/Non-Display Selecting Function (10)...2393
        Action Code Display Function (11)...2394
        Failure Code Display Function (12)...2394
      Service Mode...2396
        Switching to Service Mode and Screen Display (1)...2396
        Electrical System Fault History Display Function (ELECTRIC FAULT) (2)...2398
        Mechanical System Fault History Display Function (MACHINE FAULT) (3)...2400
        Real-Time Monitoring Function (REAL-TIME MONITOR) (4)...2401
        Real-Time Monitoring Code Tables...2404
        Engine Reduced-Cylinder Function (CYLINDER CUT-OUT) (5)...2431
        No-Injection Cranking Function (6)...2432
        Adjustment Function (TUNING) (7)...2433
        Maintenance Monitoring Function (8)...2450
        Operating Information Display Function (OPERATION INFO) (9)...2456
        Optional Device Selecting Function (10)...2459
        Machine Serial Number Input Function (11)...2463
        Model Select Function (12)...2463
        Initialize Function (13)...2464
    PM-CLINIC INSPECTION TABLE...2465
  40 TROUBLESHOOTING...2470
    POINTS TO REMEMBER WHEN TROUBLESHOOTING...2485
    SEQUENCE OF EVENTS IN TROUBLESHOOTING...2487
    PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...2488
      Precautions when Handling Electrical Equipment...2488
      Handling Electronic Control Unit...2493
      Points to Remember when Troubleshooting Electrical Circuits...2494
    ELECTRIC WIRE CODE...2495
      Classification by Thickness...2495
      Classification by Color and Code...2495
      How to Read Electric Wire Code...2496
        Type, Symbol, and Material...2496
        Dimensions...2497
    HANDLING HYDRAULIC EQUIPMENT...2498
    CHECKS BEFORE TROUBLESHOOTING...2500
      Categories and Method of Using Troubleshooting Charts...2501
      Troubleshooting Individual Electrical Circuits...2502
        Chart Use...2504
        Chart Tips...2504
      Troubleshooting Individual Hydraulic Circuits...2505
    CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...2507
      X-Type Connectors...2507
      SWP-Type Connectors...2509
      M-Type Connectors...2511
      S-Type Connectors...2513
      MIC-Type Connectors...2515
      AMP040-Type Connectors...2517
      AMP070-Type Connectors...2519
      AMP Connector...2521
      L-Type Connector...2521
      PA-Type Connector...2522
      Bendix (MS) Connector...2522
      KES1 (Automobile) Connectors...2523
      F-Type Connector...2524
      Connectors for Relay (Socket-Type)...2525
      HD30 Series Connectors...2526
      DT Series Connectors...2532
      DTM Series Connectors...2534
      DTHD Series Connectors...2534
      DTP Series Connectors...2535
      DRC26 Series Connectors...2536
      DRC12, 16 Series Connectors...2538
      AMP Connectors for Pump Controller (CH700)...2539
      BOSCH Connectors for Engine...2540
      SUMITOMO Connectors for Engine...2541
      CANNON Connector for Engine...2542
      AMP Connectors for Engine...2543
      FRAMATOME Connectors for Engine...2544
      PACKARD Connectors for Engine...2546
      DT Series Connectors for Engine...2547
    T-BRANCH BOX and T-BRANCH ADAPTER TABLE...2548
    MODE CHART...2553
    INFORMATION CONTAINED IN TESTING PROCEDURES...2556
    TROUBLESHOOTING BY FAILURE CODE...2558
      Failure Code Table...2558
    FUSE BOX AND SLOW-BLOW FUSES...2569
      Connection Table...2569
        Fuse Box 1...2569
        Fuse Box 2...2570
        Slow-Blow Fuses...2570
    FAILURE CODES...2572
      1500L0...2572
        TORQFLOW Transmission: Double Meshing...2572
      15SAL1...2573
        ECMV F Clutch: When Command Current is OFF, Fill Signal is ON...2573
      15SALH...2575
        ECMV F Clutch: When Command Current is ON, Fill Signal is OFF...2575
      15SBL1...2577
        ECMV R Clutch: When Command Current is OFF, Fill Signal is ON...2577
      15SBLH...2579
        ECMV R Clutch: When Command Current is ON, Fill Signal is OFF...2579
      15SEL1...2581
        ECMV 1st Clutch: When Command Current is OFF, Fill Signal is ON...2581
      15SELH...2583
        ECMV 1st Clutch: When Command Current is ON, Fill Signal is OFF...2583
      15SFL1...2585
        ECMV 2nd Clutch: When Command Current is OFF, FIll Signal is ON...2585
      15SFLH...2587
        ECMV 2nd Clutch: When Command Current is ON, Fill Signal is OFF...2587
      15SGL1...2589
        ECMV 3rd Clutch: When Command Current is OFF, Fill Signal is ON...2589
      15GLH...2591
        ECMV 3rd Clutch: When Command Current is ON, Fill Signal is OFF...2591
      15SHL1...2593
        ECMV 4th Clutch: When Command Current is OFF, Fill Signal is ON...2593
      15SHLH...2595
        ECMV 4th Clutch: When Command Current is ON, Fill Signal is OFF...2595
      2F00MA...2597
        Parking Brake: Malfunction...2597
      2G43ZG...2599
        Rear Accumulator: Low Oil Pressure...2599
      44K0L4...2601
        Bucket Positioner: ON/OFF Signals Disagree...2601
      AA1ANX...2605
        Air Cleaner: Clogging...2605
      AB00L6...2607
        Alternator: Signal Disagrees with Operating State of Engine...2607
      AB00MA...2609
        Alternator: Malfunction...2609
      B@BAZG...2611
        Engine: Rotation Derating by Low Engine Oil Pressure...2611
      B@BAZK...2612
        Engine Oil: Low Level...2612
      B@BCNS...2613
        Engine Coolant: Overheating...2613
      B@BCZK...2615
        Engine Coolant: Low Level...2615
      B@BEBF...2617
        Water in Fuel Error...2617
      B@C7NS...2619
        Brake Oil: Overheating...2619
      b@CENS...2621
        Torque Converter Oil: Overheating...2621
      B@CENS...2623
        Torque Converter Oil: Overheating...2623
      B@HANS...2625
        Hydraulic Oil: Overheating...2625
      CA111...2627
        Abnormality in Engine Controller...2627
      CA115...2628
        Engine Ne or Bkup Speed Sensor Error...2628
      CA122...2629
        Charge Pressure Sensor High Error...2629
      CA123...2631
        Charge Pressure Sensor Low Error...2631
      CA131...2633
        Throttle Sensor High Error...2633
      CA132...2635
        Throttle Sensor Low Error...2635
      CA144...2637
        Coolant Temperature Sensor High Error...2637
      CA145...2639
        Coolant Temperature Sensor Low Error...2639
      CA153...2641
        Charge Temperature Sensor High Error...2641
      CA154...2643
        Charge Temperature Sensor Low Error...2643
      CA155...2645
        Derating of Speed by Abnormally High Charge Temperature...2645
      CA187...2647
        Sensor Power Supply 2 Low Error...2647
      CA221...2649
        Atmospheric Pressure Sensor High Error...2649
      CA222...2651
        Atmospheric Pressure Sensor Low Error...2651
      CA227...2653
        Sensor Power Supply 2 High Error...2653
      CA234...2655
        Engine Overspeed...2655
      CA238...2656
        Ne Speed Sensor Power Supply Error...2656
      CA271...2657
        IMV/PCV1 Short Circuit...2657
      CA272...2659
        IMV/PCV1 Disconnection...2659
      CA322...2661
        Injector #1 Open/Short Error...2661
      CA323...2663
        Injector #5 Open/Short Error...2663
      CA324...2665
        Injector #3 Open/Short Error...2665
      CA325...2667
        Injector #6 Open/Short Error...2667
      CA331...2669
        Injector #2 Open/Short Error...2669
      CA332...2671
        Injector #4 Open/Short Error...2671
      CA342...2673
        Calibration Code Inconsistency...2673
      CA351...2675
        Injectors Drive Circuit Error...2675
      CA352...2677
        Sensor Power Supply 1 Low Error...2677
      CA386...2679
        Sensor Power Supply 1 High Error...2679
      CA428...2681
        Abnormally High Level in Water Sensor...2681
      CA429...2683
        Abnormally Low Level in Water Sensor...2683
      CA431...2685
        Idle Validation Switch Error...2685
      CA432...2689
        Idle Validation Action Error...2689
      CA435...2693
        Engine Oil Pressure Switch Error...2693
      CA441...2695
        Battery Voltage Low Error...2695
      CA442...2699
        Battery Voltage High Error...2699
      CA449...2701
        Common Rail Pressure High Error 2...2701
      CA451...2705
        Common Rail Pressure Sensor High Error...2705
      CA452...2707
        Common Rail Pressure Sensor Low Error...2707
      CA488...2709
        Derating of Torque by Abnormally High Charge Temperature...2709
      CA553...2710
        Common Rail Pressure High Error 1...2710
      CA559...2711
        Supply Pump Pressure Very Low Error 1...2711
      CA689...2713
        Engine Ne Speed Sensor Error...2713
      CA731...2715
        Engine Bkup Speed Sensor Phase Error...2715
      CA757...2716
        All Continuous Data Lost Error...2716
      CA778...2719
        Engine Bkup Speed Sensor Error...2719
      CA1633...2721
        KOMNET Datalink Timeout Error...2721
      CA2185...2723
        Throttle Sensor Power Supply Voltage High Error...2723
      CA2186...2725
        Throttle Sensor Power Supply Voltage Low Error...2725
      CA2249...2727
        Supply Pump Pressure Very Low Error 2...2727
      CA2311...2729
        Abnormality in IMV Solenoid...2729
      CA2555...2731
        Intake Heater Relay Disconnection Error...2731
      CA2556...2733
        Intake Heater Relay Short Circuit Error...2733
      D150KA...2735
        Emergency Steering Relay: Disconnection...2735
      D150KB...2737
        Emergency Steering Relay: Short Circuit...2737
      D150KY...2739
        Emergency Steering Relay: Short Circuit with Power Supply Line...2739
      D160KA...2741
        Backup Lamp Relay: Disconnection...2741
      D160KB...2743
        Backup Lamp Relay: Short Circuit...2743
      D191KA...2745
        Joystick Steering Neutral Safety Relay: Disconnection...2745
      D191KB...2747
        Joystick Steering Neutral Safety Relay: Short Circuit...2747
      D191KY...2749
        Joystick Steering Neutral Safety Relay: Short Circuit with Power Supply Line...2749
      D192KA...2751
        ECSS Solenoid: Disconnection...2751
      D192KB...2753
        ECSS Solenoid: Short Circuit...2753
      D192KY...2755
        ECSS Solenoid Relay: Short Circuit with Power Supply Line...2755
      D193KA...2757
        Joystick Steering Solenoid Cut Relay: Disconnection...2757
      D193KB...2759
        Joystick Steering Solenoid Cut Relay: Short Circuit...2759
      D193KY...2761
        Joystick Steering Solenoid Cut Relay: Short Circuit with Power Supply Line...2761
      D5ZHKA...2763
        Terminal C Signal: Disconnection...2763
      D5ZHKB...2767
        Terminal C Signal: Short Circuit...2767
      D5ZHKZ...2771
        Terminal C Signal: Disconnection or Short Circuit...2771
      D5ZHL6...2775
        Terminal C Signal: Signal Does Not Match Engine Running or Stopped State...2775
      DA80L4...2779
        Auto-Grease Controller: ON/OFF Signals Disagree...2779
      DAF3KK...2781
        Machine Monitor: Low Source Voltage (input)...2781
      DAF5KP...2783
        Machine Monitor: Low Output Voltage...2783
      DAFRKR...2787
        Machine Monitor: CAN Defective Communication...2787
      DAQ0KK...2791
        Transmission Controller: Low Source Voltage...2791
      DAQ0KT...2793
        Transmission Controller: Abnormality in Controller...2793
      DAQ2KK...2795
        Transmission Controller Load Power Supply Line: Low Source Voltage (input)...2795
      DAQ9KQ...2797
        Transmission Controller: Disagreement of Model Selection Signals...2797
      DAQRKR...2799
        CAN Communication with Transmission Controller: Defective Communication...2799
      DAQRMA...2802
        Transmission Controller Option Setting: Malfunction...2802
      DB2RKR...2803
        CAN Communication with Engine Controller: Defective Communication...2803
      DB90KK...2807
        Work Equipment Controller: Low Source Voltage (input)...2807
      DB90KT...2809
        Work Equipment Controller: Abnormality in Controller...2809
      DB92KK...2811
        Work Equipment Controller Load Power Supply Line: Low Source Voltage (input)...2811
      DD95KX...2813
        Work Equipment Controller Power Supply Output: Out-of-Input Signal Range...2813
      DB99KQ...2816
        Work Equipment Controller: Disagreement in Model Selection Signals...2816
      DB9RKR...2817
        CAB Communication with Work Equipment Controller: Defective Communication...2817
      DB9RMA...2820
        Work Equipment Controller Option Setting: Malfunction...2820
      DB9RMC...2821
        CAN Communication: Defective Operation...2821
      DD15LD...2825
        Switch (Panel Switch 1 n): Switch is Pressed for Long Time...2825
      DD16LD...2827
        Switch (Panel Switch 2 ‡): Switch is Pressed for Long Time...2827
      DD17LD...2829
        Switch (Panel Switch 3 <): Switch is Pressed for Long Time...2829
      DD18LD...2831
        Switch (Panel Switch 4 >): Switch is Pressed for Long Time...2831
      DD1ALD...2833
        Remote Positioner Raise/Lower Set Switch (raise): Switch is Pressed for Long Time...2833
      DD1BLD...2835
        Remote Positioner Raise/Lower Set Switch (lower): Switch is Pressed for Long Time...2835
      DD1CLD...2837
        Load Meter Subtotal Switch: Switch is Pressed for Long Time...2837
      DD1FLD...2839
        Load Meter Mode Selector Switch (A/B): Switch is Pressed for Long Time...2839
      DD1GLD...2841
        Load Meter Mode Selector Switch (+/-): Switch is Pressed for Long Time...2841
      DD1HLD...2843
        Load Meter Display Selector Switch: Switch is Pressed for Long Time...2843
      DD1NLD...2845
        Fan Reverse Switch: Switch is Pressed for Long Time...2845
      DD1NL4...2847
        Fan Automatic Reverse Switch: Switch is Pressed for Long Time...2847
      DDB6L4...2849
        Parking Brake Switch (Neutralizer): ON/OFF Signals Disagree...2849
      DDE5MA...2853
        Emergency Steering Drive Switch: Malfunction...2853
      DDK3KA...2855
        Right FNR Switch: Disconnection...2855
      DDK4KA...2858
        Joystick Steering FNR Switch: Disconnection...2858
      DDK5L4...2861
        Joystick Steering Shift UP/DOWN Switch: ON/OFF Signals Disagree...2861
      DDK6KA...2863
        FNR Lever Switch: Disconnection...2863
      DDK6KB...2866
        FNR Lever Switch: Short Circuit...2866
      DDS5KA...2869
        Steering Pressure Switch: Disconnected...2869
      DDS5KB...2871
        Steering Pressure Switch: Grounded...2871
      DDT0L4...2873
        Shift Mode Selector Switch: ON/OFF Signals Disagree...2873
      DDT4LD...2875
        Transmission Cutoff Set Switch: Switch is Pressed for Long Time...2875
      DDW9LD...2877
        Kickdown Switch: Switch is Pressed for Long Time...2877
      DDWLLD...2879
        Hold Switch: Switch is Pressed Down for Long Time...2879
      DDY0LD...2881
        Load Meter Cancel Switch: Switch is Pressed for Long Time...2881
      DF10KA...2883
        Transmission Shift Lever Switch: Disconnected...2883
      DF10KB...2887
        Transmission Shift Lever Switch: Short Circuit...2887
      DGF1KA...2891
        Transmission Oil Temperature Sensor: Disconnected...2891
      DGF1KB...2893
        Transmission Oil Temperature Sensor: Short Circuit...2893
      DGH2KX...2895
        Hydraulic Oil Temperature Sensor: Out-of-Input Signal Range...2895
      DGR2KA...2897
        Rear Brake Oil Temperature Sensor: Disconnected...2897
      DGR2KX...2899
        Rear Brake Oil Pressure Sensor: Out-of-Input Signal Range...2899
      DGT1KX...2901
        Torque Converter Oil Temperature Sensor: Out-of-Input Signal Range...2901
      DH21KA...2903
        Loader Pump Pressure Sensor: Disconnection...2903
      DH21KB...2905
        Loader Pump Pressure Sensor: Power Supply Line Short...2905
      DHPCKX...2907
        Lift Arm Cylinder Bottom Pressure Sensor: Out-of-Input Signal Range...2907
      DHPDKX...2909
        Lift Arm Cylinder Head Pressure Sensor: Out-of-Input Signal Range...2909
      DHT1KX...2911
        Transmission Cutoff Pressure Sensor: Out-of-Input Signal...2911
      DHT8KA...2913
        Steering Pump Pressure Sensor: Disconnection...2913
      DHT8KB...2915
        Steering Pump Pressure Sensor: Short Circuit...2915
      DK59KA...2917
        Lift Arm EPC Lever Potentiometer (Main): Disconnection...2917
      DK59KY...2920
        Lift Arm EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line...2920
      DK59L8...2923
        Lift Arm EPC Lever Potentiometer (Main): Analog Signals Disagree...2923
      DK5AKA...2927
        Lift Arm EPC Lever Potentiometer (Sub): Disconnection...2927
      DK5AKY...2930
        Lift Arm EPC Lever Potentiometer (Sub): Short Circuit with Power Supply LIne...2930
      DK5BKA...2933
        Bucket EPC Lever Potentiometer (Main): Disconnection...2933
      DK5BKY...2936
        Bucket EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line...2936
      DK5BL8...2939
        Bucket EPC Lever Potentiometer (Main): Analog Signals Disagree...2939
      DK5CKA...2942
        Bucket EPC Lever Potentiometer (Sub): Disconnection...2942
      DK5CKY...2945
        Bucket EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line...2945
      DK5FKA...2948
        Joystick Steering EPC Lever Potentiometer (Main): Disconnection...2948
      DK5FKY...2951
        Joystick Steering EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line...2951
      DK5GKA...2954
        Joystick Steering EPC Lever Potentiometer (Sub): Disconnection...2954
      DK5GKY...2957
        Joystick Steering EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line...2957
      DK5FL8...2960
        Joystick Steering EPC Lever Potentiometer (Main): Analog Signals Disagree...2960
      DKA0KA...2963
        Lift Arm Angle Sensor: Disconnection...2963
      DKA0KY...2967
        Lift Arm Angle Sensor: Short Circuit with Power Supply Line...2967
      DKA0L0...2969
        Lift Arm Angle Sensor: Double Meshing...2969
      DLT3KA...2971
        Transmission Output Shaft Speed Sensor: Disconnection...2971
      DLT3LC...2973
        Transmission Output Shaft Speed Sensor: Out-of-Input Signal Range...2973
      DT20KB...2975
        Transmission Cutoff Indicator Lamp: Short Circuit...2975
      DUM1KB...2977
        Remote Positioner Raise Set Indicator Lamp: Short Circuit...2977
      DUM2KB...2979
        Remote Positioner Lower Set Indicator Lamp: Short Circuit...2979
      DV00KB...2981
        Alarm Buzzer: Short Circuit...2981
      DW4PKA...2983
        Lift Arm Raise EPC Solenoid: Disconnection...2983
      DW4PKB...2985
        Lift Arm Raise EPC Solenoid: Short Circuit...2985
      DW4PKY...2987
        Lift Arm Raise EPC Solenoid: Short Circuit with Power Supply Line...2987
      DW4QKA...2989
        Lift Arm Lower EPC Solenoid: Disconnection...2989
      DW4QKB...2991
        Lift Arm Lower EPC Solenoid: Short Circuit...2991
      DW4QKY...2993
        Lift Arm Lower EPC Solenoid: Short Circuit with Power Supply Line...2993
      DW4RKA...2995
        Bucket Tilt EPC Solenoid: Disconnection...2995
      DW4RKB...2997
        Bucket Tilt EPC Solenoid: Short Circuit...2997
      DW4RKY...2999
        Bucket Tilt EPC Solenoid: Short Circuit with Power Supply Line...2999
      DW4SKA...3001
        Buck Dump EPC Solenoid: Disconnection...3001
      DW4SKB...3003
        Bucket Dump EPC Solenoid: Short Circuit...3003
      DW4SKY...3005
        Bucket Dump EPC Solenoid: Short Circuit with Power Supply Line...3005
      DW7BKA...3007
        Fan Reverse Solenoid: Disconnection...3007
      DW7BKB...3009
        Fan Reverse Solenoid: Short Circuit...3009
      DW7BKY...3011
        Fan Reverse Solenoid: Short Circuit with Power Supply Line...3011
      DWM1KA...3013
        Work Equipment Neutral Lock Solenoid: Disconnection...3013
      DWM1KB...3015
        Work Equipment Neutral Lock Solenoid: Short Circuit...3015
      DWM1KY...3017
        Work Equipment Neutral Lock Solenoid: Short Circuit with Power Supply Line...3017
      DWN6KA...3019
        Lift Arm Raise Magnet Detent Solenoid: Disconnection...3019
      DWN6KB...3021
        Lift Arm Raise Magnet Detent Solenoid: Short Circuit...3021
      DWN6KY...3023
        Lift Arm Raise Magnet Detent Solenoid: Short Circuit with Power Supply Line...3023
      DWN7KA...3025
        Lift Arm Float Magnet Detent Solenoid: Disconnection...3025
      DWN7KB...3027
        Lift Arm Float Magnet Detent Solenoid: Short Circuit...3027
      DWN7KY...3029
        Lift Arm Float Magnet Detent Solenoid: Short Circuit with Power Supply Line...3029
      DWN8KA...3031
        Bucket Tilt Magnet Detent Solenoid: Disconnection...3031
      DWN8KB...3033
        Bucket Tilt Magnet Detent Solenoid: Short Circuit...3033
      DWN8KY...3035
        Bucket Tilt Magnet Detent Solenoid: Shorted with the Power Source...3035
      DX16KA...3037
        Fan Pump EPC Solenoid: Disconnection...3037
      DX16KB...3039
        Fan Pump EPC Solenoid: Short Circuit...3039
      DX16KY...3041
        Fan Pump EPC Solenoid: Short Circuit with Power Supply Line...3041
      DXH1KA...3043
        Lockup ECMV Solenoid: Disconnection...3043
      DXH1KB...3045
        Lockup ECMV Solenoid: Short Circuit...3045
      DXH1KY...3047
        Lockup ECMV Solenoid: Short Circuit with Power Supply Line...3047
      DXH4KA...3049
        1st Clutch ECMV Solenoid: Disconnection...3049
      DXH4KB...3051
        1st Clutch ECMV Solenoid: Short Circuit...3051
      DXH4KY...3053
        1st Clutch ECMV Solenoid: Short Circuit with Power Supply Line...3053
      DXH5KA...3055
        2nd Clutch ECMV Solenoid: Disconnection...3055
      DXH5KB...3057
        2nd Clutch ECMV Solenoid: Short Circuit...3057
      DXH5KY...3059
        2nd Clutch ECMV Solenoid: Short Circuit with Power Supply Line...3059
      DXH6KA...3061
        3rd Clutch ECMV Solenoid: Disconnection...3061
      DXH6KB...3063
        3rd Clutch ECMV Solenoid: Short Circuit...3063
      DXH6KY...3065
        3rd Clutch ECMV Solenoid: Short Circuit with Power Supply Line...3065
      DXH7KA...3067
        R Clutch ECMV Solenoid: Disconnection...3067
      DXH7KB...3069
        R Clutch ECMV Solenoid: Short Circuit...3069
      DXH7KY...3071
        R Clutch ECMV Solenoid: Short Circuit with Power Supply Line...3071
      DXH8KA...3073
        F Clutch ECMV Solenoid: Disconnection...3073
      DXH8KB...3075
        F Clutch ECMV Solenoid: Short Circuit...3075
      DXH8KY...3077
        F Clutch ECMV Solenoid: Short Circuit with Power Supply Line...3077
      DXHHKA...3079
        4th Clutch ECMV Solenoid: Disconnection...3079
      DXHHKB...3081
        4th Clutch ECMV Solenoid: Short Circuit...3081
      DXHHKY...3083
        4th Clutch ECMV Solenoid: Short Circuit with Power Supply Line...3083
      DXHLKA...3085
        Joystick Steering Right EPC Solenoid: Disconnection...3085
      DXHLKB...3087
        Joystick Steering Right EPC Solenoid: Short Circuit...3087
      DXHLKY...3089
        Joystick Steering Right EPC Solenoid: Short Circuit with Power Supply Line...3089
      DXHMKA...3091
        Joystick Steering Left EPC Solenoid: Disconnection...3091
      DXHMKB...3093
        Joystick Steering Left EPC Solenoid: Short Circuit...3093
      DXHMKY...3095
        Joystick Steering Left EPC Solenoid: Short Circuit with Power Supply Line...3095
      DY30MA...3097
        Motor-Driven Emergency Steering Pump Failure (during Operation of machine)...3097
      DY30MC...3100
        Motor-Driven Emergency Steering Pump Failure (Malfunction in Manual Mode)...3100
    TROUBLESHOOTING: E-MODE...3103
      Troubleshooting Electrical System...3103
        Information in Troubleshooting Table...3103
      E-1...3105
        Engine Does Not Start...3105
      E-2...3111
        Wiper Does Not Operate...3111
      E-3...3115
        Windshield Washer Does Not Operate...3115
      E-4...3119
        Headlamp, Clearance Lamp, Tail Lamp, and License Lamp Do Not Light Up or Go Off...3119
      E-5...3127
        Working Lamp Does Not Light Up or Go Off...3127
      E-6...3133
        Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off...3133
      E-7...3139
        Brake Lamp Does Not Light or It Keeps Lighting Up...3139
      E-8...3142
        Backup Lamp Does Not Light or It Keeps Lighting Up...3142
      E-9...3145
        Backup Buzzer Does Not Sound or It Keeps Sounding...3145
      E-10...3148
        Horn Does Not Sound or It Keeps Sounding...3148
      E-11...3151
        Alarm Buzzer Does Not Sound or It Keeps Sounding...3151
      E-12...3153
        Air Conditioner Does Not Operate or Stop...3153
      E-13...3157
        KOMTRAX System Does Not Work Properly...3157
          Indicator Lamps of KOMTRAX Terminal...3159
      E-14...3161
        When Kickdown Switch is Turned On, Kickdown Operation Does Not Start...3161
      E-15...3163
        When Hold Switch is Pressed, Holding Operation Does Not Start...3163
      E-16...3165
        Transmission Kept in Neutral or Brake Drags when Directional Lever is Operated While Parking Brake is Applied...3165
      E-17...3167
        Transmission Cutoff Mode Cannot Be Set or Reset...3167
      E-18...3169
        Transmission Cutoff Set Cannot be Reset...3169
      E-19...3171
        FNR Switch Mode Cannot Be Set or Reset...3171
      E-20...3173
        Fan Reverse Function Cannot Be Used or Reset...3173
      E-21...3175
        Discharge from Loader Pump Does Not Rise from Minimum Level...3175
      E-22...3177
        ECSS Function Cannot Be Used or Reset...3177
      E-23...3179
        When Parking Brake is Turned On, Parking Brake Indicator Lamp Does Not Light Up...3179
      E-24...3183
        When Emergency Brake Operates, Brake Oil Pressure Caution Lamp Does Not Operate...3183
      E-25...3185
        Air Cleaner Clogging Indicator Lamp Does Not Light Up...3185
      E-26...3187
        Radiator Coolant Level Caution Lamp Does Not Light Up...3187
      E-27...3189
        Hydraulic Oil Temperature Gauge Does Not Rise and Hydraulic Oil Temperature Caution Lamp Does Not Light Up...3189
      E-28...3191
        Torque Converter Oil Temperature Gauge Does Not Rise and Torque Converter Oil Temperature Caution Lamp Does Not Light Up...3191
      E-29...3193
        Steering Oil Pressure Caution Lamp Does Not Light Up...3193
      E-30...3195
        Abnormality in Switch (n) (Panel Switch 1) Input...3195
      E-31...3197
        Abnormality in Switch (‡) (Panel Switch 2) Input...3197
      E-32...3199
        Abnormality in Switch (<) (Panel Switch 3) Input...3199
      E-33...3201
        Abnormality in Switch (>) (Panel Switch 4) Input...3201
    TROUBLESHOOTING: H-MODE...3203
      Troubleshooting Hydraulic and Mechanical Systems...3203
        Using Troubleshooting Chart...3203
      Failure Codes and Causes Table...3205
      H-1...3209
        Machine Does Not Start...3209
      H-2...3211
        Torque Converter Lockup is Not Switched OFF (Engine Stalls)...3211
      H-3...3212
        Torque Converter Lockup is Not Switched ON...3212
      H-4...3213
        Travel Speed is Slow, Thrusting Force is Weak, Uphill Traveling Power is Weak, Gear is Not Shifted...3213
      H-5...3217
        Large Shocks When Starting and Shifting Gears...3217
      H-6...3221
        Large Time Lag When Starting and Shifting Gear...3221
      H-7...3225
        Torque Converter Oil Temperature is High...3225
      H-8...3226
        Steering Does Not Turn...3226
      H-9...3227
        Steering Does Not Turn (Joystick Steering, if equipped)...3227
      H-10...3228
        Steering Response is Poor...3228
      H-11...3229
        Steering, Turning Response is Poor (Joystick Steering, if Equipped)...3229
      H-12...3230
        Steering is Heavy...3230
      H-13...3231
        When Machine Turns, It Shakes or Jerks...3231
      H-14...3232
        When Machine Turns, It Shakes or Jerks (Joystick Steering, if Equipped)...3232
      H-15...3233
        Wheel Brake Does Not Work or Does Not Work Well...3233
      H-16...3234
        Wheel Brake is Not Released or It Drags...3234
      H-17...3235
        Parking Brake Does Not Work or Does Not Work Well...3235
      H-18...3236
        Parking Brake is Not Released or It Drags...3236
      H-19...3237
        Lift Arm Does Not Rise...3237
      H-20...3238
        Lift Arm Speed is Low or Rising Force is Insufficient...3238
      H-21...3239
        When Rising, Lift Arm Starts to Move Slowly at a Specific Height...3239
      H-22...3239
        Lift Arm Cylinder Cannot Hold Down Bucket (Bucket Floats)...3239
      H-23...3239
        Hydraulic Drifts of the Lift Arm Are Large...3239
      H-24...3240
        Lift Arm Wobbles During Operation...3240
      H-25...3241
        Bucket Does Not Tilt Back...3241
      H-26...3242
        Bucket Speed is Low or Tilting-Back Force Is Insufficient...3242
      H-27...3243
        Bucket Starts to Operate Slowly in the Midst of Tilting Back...3243
      H-28...3243
        Bucket Cylinder Cannot Hold Down the Bucket...3243
      H-29...3243
        Hydraulic Drifts of the Bucket Are Large...3243
      H-30...3244
        Bucket Wobbles During Travel with Load...3244
      H-31...3245
        Lift Arm and Bucket Control Levers Do Not Move Smoothly and Are Heavy...3245
      H-32...3246
        During Operation of Machine, Engine Speed Drops Remarkably or Engine Stalls...3246
      H-33...3246
        Large Shocks When Work Equipment Starts and Stops...3246
      H-34...3246
        When Work Equipment Circuit is Relieved Singly, Other Work Equipment Moves...3246
      H-35...3247
        ECSS Does Not Operate; Pitching and Bouncing Occur...3247
  50 DISASSEMBLY AND ASSEMBLY...3248
    HOW TO READ THIS MANUAL...3252
      Removal and Installation of Assemblies...3252
      Disassembly and Assembly of Assemblies...3254
    COATING MATERIALS LIST...3256
    SPECIAL TOOLS LIST...3259
    SKETCHES OF SPECIAL TOOLS...3262
    CONNECTOR REPAIR PROCEDURES...3268
      Stripping Insulation...3268
      Wire Inspection...3268
      Contact Terminal Removal (HD30 Type)...3269
      Crimping Contact Terminal (HD30 Type)...3270
      Insertion Of Contact Terminal (HD30 Type)...3271
      Contact Terminal Removal (DT Type)...3272
      Crimping Contact Terminal (DT Type)...3273
      Insertion Of Contact Terminal (DT Type)...3274
    ENGINE AND COOLING SYSTEM...3275
      Alternator...3275
      Crankshaft...3275
      Camshaft...3275
      Engine Front Seal...3275
      Engine Oil Cooler...3275
      Engine Rear Seal...3275
      Starting Motor...3275
      Thermostat...3275
      Turbocharger...3275
      Water Pump...3275
      Cylinder Head...3276
        Removal...3276
        Installation...3282
      Engine Hood...3289
        Removal...3289
        Installation...3291
      Radiator...3292
        Removal...3292
        Installation...3293
      Air Aftercooler...3294
        Removal...3294
        Installation...3295
      Hydraulic Oil Cooler...3296
        Removal...3296
        Installation...3297
      Engine...3298
        Removal...3298
        Installation...3303
      Cooling Fan and Fan Motor...3305
        Removal...3305
        Installation...3308
    FUEL SUPPLY SYSTEM...3309
      Fuel Supply Pump...3309
        Removal...3309
        Installation...3310
      Fuel Injector...3311
        Removal...3311
        Installation...3314
      Fuel Tank...3319
        Removal...3319
        Installation...3321
    POWER TRAIN...3322
      Torque Converter and Transmission Assembly...3322
        Removal...3322
        Installation...3329
      Torque Converter (Standard Specification)...3330
        Disassembly...3330
        Assembly...3333
      Torque Converter (Lockup Specification)...3336
        Disassembly...3336
        Assembly...3339
      Transmission...3344
        Disassembly...3344
        Assembly...3354
      Clutch Pack...3365
        Forward and Reverse Clutch Pack: Disassembly...3365
        1st and 4th Clutch Pack: Disassembly...3369
        2nd and 3rd Gear Clutch Pack: Disassembly...3372
        Forward and Reverse Clutch Pack: Assembly...3378
        1st and 4th Clutch Pack: Assembly...3382
        2nd and 3rd Clutch Pack: Assembly...3386
      Parking Brake...3391
        Disassembly...3391
        Assembly...3396
      Front Axle...3403
        Removal...3403
        Installation...3404
      Rear Axle...3405
        Removal...3405
        Installation...3408
      Axle Housing...3410
        Disassembly...3410
        Assembly...3415
      Differential Assembly...3422
        Disassembly...3422
        Assembly...3431
    STEERING SYSTEM...3447
      Steering Valve Assembly...3447
        Removal...3447
        Installation...3449
    BRAKING SYSTEM...3450
      Parking Brake Discs and Plates...3450
        Removal...3450
        Installation...3452
    UNDERCARRAGE AND FRAME...3453
      Center Hinge Pin...3453
        Removal...3453
        Installation...3458
      Counterweight...3463
        Removal...3463
        Installation...3465
    HYDRAULIC SYSTEM...3466
      Work Equipment Control Valve...3466
        Removal...3466
        Installation...3468
      Power Train Pump and Work Equipment Pump Assembly...3469
        Removal...3469
        Installation...3469
      Steering Pump And Cooling Fan Pump Assembly...3470
        Removal...3470
        Installation...3471
      Hydraulic Tank...3472
        Removal...3472
        Installation...3475
    WORK EQUIPMENT...3476
      Work Equipment Assembly...3476
        Removal...3476
        Installation...3479
      Hydraulic Cylinder...3481
        Disassembly...3481
        Assembly...3485
    CAB AND ATTACHMENTS...3490
      Cab and Floor Frame...3490
        Removal...3490
        Installation...3493
      Cab Glass (Stuck Glass)...3494
        Removal...3494
        Installation...3495
      Operator Seat Assembly (Standard Specification) (ISRING HAUSEN)...3503
        Disassembly...3503
        Assembly...3510
      Operator Seat Assembly (GRAMMER)...3515
        Upper Seat...3515
        Suspension...3523
    AIR CONDITIONER UNIT ASSEMBLY...3551
      Removal...3551
      Installation...3555
    ELECTRICAL SYSTEM...3556
      Engine Controller Assembly...3556
        Removal...3556
        Installation...3556
  90 DIAGRAMS AND SCHEMATICS...3558
    AUTOMATIC GREASING...3560
      Auto-Grease Circuit Diagram...3560
    HYDRAULIC SYSTEM...3561
      Power Train Hydraulic Circuit Diagram...3561
        Without Lockup Clutch...3561
        With Lockup Clutch...3561
      Hydraulic Circuit Diagram...3562
    ELECTRICAL SYSTEM...3563
      Machine Monitor System Circuit Diagram...3563
      Transmission Controller System Circuit Diagram...3564
      Work Equipment Controller System Circuit Diagram...3565
      Work Equipment Controller System Electrical Circuit Diagram...3566
      Electrical Circuit Diagram (1/14)...3567
      Electrical Circuit Diagram (2/14)...3568
      Electrical Circuit Diagram (3/14)...3569
      Electrical Circuit Diagram (4/14)...3570
      Electrical Circuit Diagram (5/14)...3571
      Electrical Circuit Diagram (6/14)...3572
      Electrical Circuit Diagram (7/14)...3573
      Electrical Circuit Diagram (8/14)...3574
      Electrical Circuit Diagram (9/14)...3575
      Electrical Circuit Diagram (10/14)...3576
      Electrical Circuit Diagram (11/14)...3577
      Electrical Circuit Diagram (12/14)...3578
      Electrical Circuit Diagram (13/14)...3579
      Electrical Circuit Diagram (14/14)...3580
      Connector List and Stereogram...3581
        Chassis...3581
        Engine and Transmission...3582
        Operator’s Compartment...3583
CEBM022703 - Wheel Loader WA380-6 Shop Manual...3584
  CEBM022703 - WA380-6 S/N A54001-UP.pdf...0
    01 GENERAL...3646
      SPECIFICATIONS...3648
        Dimension Drawing...3648
        Specification Tables...3650
      WEIGHT TABLE...3655
      FUEL, COOLANT, AND LUBRICANTS...3657
    10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...3660
      ENGINE AND COOLING SYSTEM...3665
        Engine and Transmission Mounting...3665
          Torque Values...3666
        Cooling System...3667
          Specifications...3667
        Cooling Fan Pump...3669
          Type: LPV30...3669
          Torque Values...3670
          Torque Values...3671
          Function...3672
          Structure...3672
          Operation...3673
          Control of Delivery...3673
        Servo Valve...3674
          Torque Values...3674
          Function...3675
        Cooling Fan Motor System...3677
          Type: LMF28...3677
          Specifications...3678
          Torque Values...3678
        Hydraulic Motor...3680
          Function...3680
          Principle of Operation...3680
        Suction Valve...3681
          Function...3681
          Operation...3681
        Reversible Valve...3682
        Safety Valve...3683
          Function...3683
          Operation...3683
      POWER TRAIN SYSTEM...3684
        Drive Line Components...3684
          Outline...3684
        System Diagram...3685
          Outline...3686
        Drive Shaft System...3687
          Torque Values...3687
          Outline...3687
        Power Train Piping System...3688
        Torque Converter...3689
          Without Lockup Clutch...3689
            Specifications...3689
            Torque Values...3690
          Power Transmitting Route...3691
          Oil Flow...3691
          With Lockup Clutch...3692
            Specification...3692
            Torque Values...3694
        Torque Flow...3695
          When Lockup Clutch Is Disengaged...3695
          When Lockup Clutch Is Engaged...3695
          Oil Flow...3696
        Transmission...3697
          With Lockup Clutch...3697
            Torque Values...3698
            Outline...3699
            Torque Values...3702
            Torque Values...3706
        Forward and Reverse Clutches...3707
          Without Lockup Clutch...3707
          With Lockup Clutch...3708
          1st and 4th Clutches...3709
          2nd and 3rd Clutches...3710
          Operation of Clutch Pack...3711
            When clutch is engaged...3711
            When clutch is disengaged...3711
        Transmission Torque Flow Route...3713
          Forward 1st Gear Speed...3713
          Forward 2nd Gear Speed...3714
          Forward 3rd Gear Speed...3716
          Forward 4th Gear Speed...3717
          Reverse 1st Gear Speed...3719
        Flow Control Valve...3720
          Torque Values...3722
          Operation...3722
          Valve Assembly...3723
            Torque Values...3724
        ECMV System...3725
          For R, 1st, and 2nd Clutches...3725
            Torque Values...3726
          For F, 3rd, 4th, and Lockup Clutches...3727
          ECMV For Gear Speed Clutch...3729
            Outline of ECMV...3729
            ECMV and Proportional Solenoid...3729
            ECMV and Fill Switch...3729
            Operation of ECMV...3730
            Before Shifting Gear (when draining) (Range A in chart)...3730
            During filling (Range B in chart)...3731
            Pressure regulation (Range C in chart)...3731
          ECMV for Lockup Clutch...3732
            Outline...3732
            Operation...3732
            When Traveling in Direct Range...3733
            During Filling...3733
            Pressure Adjustment...3733
        Main and Torque Converter Relief Valve System...3735
          Torque Values...3736
          Outline...3737
            Torque Converter Relief Valve...3737
            Main Relief Valve...3737
          Operation...3737
            Torque Converter Relief Valve...3737
            Operation of Main Relief Valve...3737
      DRIVE AXLE SYSTEM...3738
        Front Axle Assembly...3738
        Rear Axle Assembly...3739
        Front Differential...3741
          Torque Values...3742
        Rear Differential...3743
          Torque Values...3744
          Outline...3745
          While Machine is Traveling Straight...3745
          When Machine Is Turning...3745
        Limited Slip Differential...3746
        Front Axle Carrier...3747
          Torque Values...3748
        Rear Axle Carrier...3749
          Torque Values...3750
          Operation of Limited Slip Differential...3751
          Generation of Braking Torque by Right / Left Side Gears (5)...3751
          While Machine is Traveling Straight...3751
          When Machine Is Turning...3752
        Final Drive...3753
          Outline...3753
          Torque Values...3754
      STEERING SYSTEM...3755
        Steering Piping Diagram...3755
        Steering Column...3756
          Torque Values...3756
        Steering Pump...3757
          Type: LPV63...3757
          Torque Values...3758
          Pump Unit...3759
            Torque Values...3760
            Function...3761
            Structure...3761
            Operation of Pump...3762
            Control of Discharge Amount...3763
          Servo Valve...3764
            Torque Values...3766
          LS Valve...3767
            Function...3767
          PC Valve...3767
            Function...3767
            Operation of Spring...3768
            When pump pressure (PA) is low...3768
            When pump pressure (PA) is high...3769
        Steering Valve...3771
          Operation of Flow Amplifier...3775
            When Spool is at Neutral (when Orbitrol valve is not in operation)...3775
            When Spool is in Operation (when oil flows in port (Pa))...3775
            When Spool is Returned (when steering wheel is stopped)...3776
          Operation of Flow Control Spool...3777
            When Steering Spool is at Neutral Position...3777
            When Steering Spool Operates...3778
          Operation of Steering Valve...3779
            At Neutral...3779
            Turning Left...3780
            Turning Right...3781
          Steering Relief Valve...3782
            Function...3782
            Operation...3782
          Overload Relief Valve...3783
            Function...3783
            Operation as Relief Valve...3783
            Operation as Suction Valve...3784
          Relief Valve...3784
            Function...3784
        Orbitrol Valve...3785
          Torque Values...3785
          Outline...3786
          Structure...3786
          Connection of Hand Pump and Sleeve...3787
          Role of Centering Spring...3788
        Stop Valve...3789
        Steering Relief Valve...3790
          Torque Values...3790
          Outline...3790
        Steering Cylinder...3791
        Emergency Steering Motor...3793
          Function...3793
          Specifications...3793
        Emergency Steering Pump (If Equipped)...3794
          Type: SBL (1) 21...3794
          Torque Value...3794
          Function...3794
        Joystick Steering Lever Linkage...3795
        Steering Electric Lever...3796
          Function...3796
        Joystick EPC Valve...3797
          Torque Values...3797
          Function...3797
        Multi-Function Lever & Joystick Lever (Modification)...3798
          Required...3798
          Procedure...3799
      SERVICE BRAKING SYSTEM...3800
        Brake Piping Diagram...3800
        Charge Valve...3801
          Torque Value...3801
          Torque Values...3804
          Function...3804
          Operation...3805
          When Oil is Not Supplied to Accumulator (cut-out state)...3805
          When Oil is Supplied to Accumulator (cut-in state)...3806
          When Cut-out Pressure is Reached...3807
          Main Relief Valve (R1)...3807
          PPC Relief Valve (R3)...3808
          Sequence Valve (H1)...3808
          Shuttle Valve (S1)...3808
        Brake Valve...3809
          Outline...3809
          Operation...3810
          When the Brake Pedal is Depressed...3810
          When Brake on One Side is Operated...3811
          Balancing Operation...3812
          When Brake Pedal is Released...3813
        Accumulator (for Brakes)...3814
          Function...3814
          Specifications...3814
        Front Brake...3815
          Outline...3816
        Rear Brake...3817
          Outline...3818
          Operation...3818
          When Brake is Operated...3818
          When Brake is Released...3818
      PARKING BRAKE SYSTEM...3819
        Brake Control...3819
          Outline...3820
        Parking Brake Unit...3821
          Outline...3822
          Torque Values...3822
        Parking Brake Solenoid Valve...3823
          Torque Values...3823
          Operation...3824
          When Parking Brake is Applied (When solenoid is de-energized)...3824
          When Parking Brake is Released (When solenoid is energized)...3824
        Emergency Parking Brake Release Valve...3825
          Function...3825
      UNDERCARRIAGE AND FRAME...3826
        Axle Mounting and Center Hinge Pin...3826
          Torque Values...3826
          Outline...3826
          Torque Values...3827
        Tires...3831
          Radial Ply Tire...3831
          Bias Tire...3831
      HYDRAULIC SYSTEM...3833
        Piping Diagram...3833
          Outline...3835
        Work Equipment Control Lever System...3836
        Multi-Function Mono-Lever Type...3837
        Hydraulic Tank...3839
          Specifications...3840
          Tank Vent System...3840
        Power Train Pump...3841
          Type: SDL (30)80...3841
          Outline...3841
        Work Equipment Pump...3843
          Type: LPV90...3843
          Torque Values...3844
          Pump Unit...3845
          Servo Valve...3847
            Torque Values...3850
            Function...3851
            Structure...3851
            Operation of Pump...3852
            Control of Delivery...3853
          LS Valve...3853
            Function...3853
          PC valve...3854
            Function...3854
            Operation...3854
            When Load is Light (Fig.1)...3855
            When Load is Heavy (Fig.2)...3855
            When Balanced (Fig.3)...3856
        Work Equipment Control Valve...3857
          Outline...3857
          4-Spool Valve...3859
            General View...3859
            Torque Values...3860
            Sectional View of Valve (1/7)...3861
            Torque Values...3862
            Sectional View of Valve (2 /7)...3863
            Sectional View of Valve (3/7)...3865
            Sectional View of Valve (4/7)...3867
            Sectional View of Valve (5/7)...3869
            Sectional View of Valve (6/7)...3871
            Sectional View of Valve (7/7)...3873
        CLSS...3875
          Outline of CLSS...3875
            Features...3875
            Structure...3875
          Basic Principle...3876
            Pump Swash Plate Angle Control...3876
          Pressure Compensation Control...3877
        Function and Operation of Each Valve...3878
          Hydraulic Circuit Diagram of Valves...3878
          Unload Valve...3879
            When Control Valve is at Neutral Position...3879
            When Control Valve is Controlled Finely...3880
            When Control Valve is Operated...3881
          Work Equipment Valve (Supply of LS Pressure)...3882
            Work Equipment Valve (Lift Arm)...3882
            Work Equipment Valve (Bucket and Service)...3883
          LS Bypass Plug...3884
          Pressure Compensation Valve...3885
          Lift Arm Regeneration Circuit...3889
            When Lift Arm is Lowered...3889
            Function...3890
            Operation...3890
          Variable Lift Check Valve...3891
            Function...3891
            Operation...3891
        ECSS Control Valve...3892
          Function...3892
          Operation...3892
          Restriction on Lift Arm Raise Stroke...3893
          Function...3894
          Operation...3894
        Accumulator Charge Valve...3895
          Pressure...3896
          When Valve is in Neutral and (P) is Low...3897
          Function...3897
          Operation...3897
          When Load Pressure (P) is High...3898
          Operation...3898
        PPC Valve...3899
          Work Equipment PPC Valve...3899
          Operation...3901
          When In Neutral...3901
          During Fine Control...3902
        Stabilizer Valve...3904
          Function...3904
          When in Neutral...3905
          Operation...3905
          Main Spool (9) is Moved from Neutral to Operating Position...3906
          Operation...3906
          Main Spool (9) is Moved from Operating Position to Neutral...3908
          Operation...3908
        Work Equipment PPC Cutoff Solenoid Valve...3909
          Outline...3909
          Operation...3910
        Accumulator (for PPC Circuit)...3911
          Outline...3911
          Specifications...3911
        Accumulator (for ECSS)...3912
          Function...3912
          Specifications...3912
      WORK EQUIPMENT...3913
        Work Equipment Linkage...3913
        Bucket...3915
        Bucket Positioner and Boom Kickout...3917
          Bucket Positioner...3918
          Boom Kick-out...3918
          Proximity Switch...3919
            When Bucket Is Tilted...3919
            Function of Proximity Switch...3921
            When Lift Arm Is Raised...3922
            Function of Proximity Switch...3924
        Work Equipment Cylinders...3925
          Lift Cylinder...3925
          Bucket Cylinder...3925
      CAB ENVIRONMENT...3926
        ROPS Cab...3926
        Air Conditioner...3927
          Air Conditioner Piping Diagram...3927
            Specifications...3928
          Refrigerant Circuit Diagram...3929
          Air Conditioner Unit...3930
            (Automatic Air Conditioner)...3930
            Outline...3931
            Cooler...3931
            Heater...3931
            Functions of Major Components...3931
            Evaporator...3931
            Heater Core...3931
            Expansion Valve...3931
            Blower Controller...3931
            Blower Motor Relay...3931
            Compressor Clutch Relay...3931
            Air Mix Damper Actuator...3931
            Mode Selector Damper Actuator...3932
            Evaporator Temperature Sensor...3932
            Dual Pressure Switch...3932
            Sunlight Sensor...3932
          Blower and Intake Unit...3933
            Automatic Air Conditioner...3933
            Functions of Major Components...3933
          Refrigerant Compressor...3934
            Function...3934
            Specifications...3934
          Condenser...3935
            Function...3935
            Specifications...3935
          Receiver...3936
            Function...3936
            Specifications...3936
          Air Conditioner Panel...3937
            Display Unit...3937
            Switch Block...3938
            Outline...3939
      ELECTRICAL SYSTEM...3941
        Machine Monitor System...3941
          Outline...3941
          Operator Mode...3941
          Service Mode...3942
          System Circuit Diagram...3943
          Machine Monitor...3944
            Speedometer Specification...3944
          Items Displayed on Monitor...3945
        Machine Monitor Operation Switches...3954
          Setting Machine Monitor...3955
          Troubleshooting Function...3955
          Character Display Function...3956
          Operator Mode Functions...3957
            Self-Check Screen (0th layer)...3957
            Normal Screen (1st layer)...3957
            Failure Code Screen (1st layer)...3958
            Display of Functions Available for the Operator (2nd layer or below)...3959
          Service Mode Functions...3960
            Procedure for Switching to Service Mode...3960
            Service Mode Menu...3961
            Electrical System Failure History Display Function (ELECTRIC FAULT)...3962
            Mechanical System Failure History Display Function (MACHINE FAULT)...3962
            Real-Time Monitoring Function (REAL-TIME MONITOR)...3962
            Engine Reduced-Cylinder Function (CYLINDER CUT-OUT)...3962
            No Injection Cranking Function (NO INJECTION)...3963
            Adjustment Function (TUNING)...3963
            Maintenance Monitoring Function (MAINTENANCE MONITOR)...3963
            Operating Information Display Function (OPERATION INFO)...3963
            Optional Device Selecting Function (OPTIONAL SELECT)...3964
            Machine Serial Number Input Function (MACHINE No. SET)...3964
            Model Selection Function (MACHINE)...3964
            Initialize Function (INITIALIZE)...3964
          Input and Output Signals...3965
        Transmission Controller System...3973
          Gearshifting Control Function...3973
            Electronic Modulation Function...3973
            Gearshifting Display Function...3973
            Automatic Gearshifting Function...3974
            Auto-Shift Points Table...3975
            Auto-Shift Points...3979
            Shift Hold Function...3981
            Kickdown Function...3981
            Torque Converter Lockup Function...3982
            Lockup Operating Points Table...3984
              Forward...3984
              Reverse...3986
            Hunting Protection Function...3988
            Changing Shift Points...3988
            4th Gear Speed Derating Function...3988
            Transmission Controller Protection Function...3989
            Shift-Down Protection Function...3990
            Engine Overrun Prevention Function...3990
            Maximum Travel Speed Derating Function...3991
            Neutralizer Function...3991
            Engine Control Function...3991
            Economy Operation Pilot Lamp Function...3992
          Cooling Fan Control Function...3993
            Fan Control...3994
            Pump Protection Function...3994
            Control at Start of Engine...3995
            Fan Reverse Rotation Function...3996
          Work Equipment Pump Swash Plate Control Function...3998
            Engine Stop Prevention Control at Low Idle...3998
            Pickup Auxiliary Function when Engine Speed is Low...3999
          Transmission Cutoff Function...4000
          ECSS Function...4002
            Outline...4002
            Setting Method...4002
            Operation...4003
          Electric Emergency Steering Function...4004
            Outline...4004
            Setting method...4005
            Self-Check Operation of Emergency Steering...4005
          Directional Selector Switch Control Function...4006
            Operation of Directional Selector Switch...4006
            Safety Function at Start of Engine...4007
            Setting Method...4007
          Multi-Function Mono Lever Function...4008
            Operation of FNR Switch...4008
            Safety Function at Start of Engine...4009
            Shift Hold Function...4009
            Kickdown Function...4009
            Setting Method...4009
          Joystick Steerin Function...4010
            Operation of Directional Selector Switch...4011
            Safety Function at Start of Engine...4011
            Shift-Up and Shift-Down Function...4012
            Setting Method...4012
          System Circuit Diagram...4013
          Transmission Controller...4014
            Input and Output Signals...4014
        Work Equipment Controller System...4016
          Safety Function for Starting Engine...4016
          Safety Function for Selecting Joystick Steering System...4016
          Steering Speed Selecting Function...4017
          Travel Speed-Sensitive Steering Function...4017
          Adjusting Starting Current...4017
          Setting Method...4017
          Troubleshooting Function...4017
          System Circuit Diagram...4018
          Work Equipment Controller...4019
            Input and Output Signals...4019
      ELECTRONIC TRANSMISSION CONTROL...4021
        Function...4022
        Combination Switch...4023
          Outline...4023
          Function...4023
          Operation...4024
      KICKDOWN AND HOLD SWITCH...4025
        Load Meter Cancel Switch and Load Meter Subtotal Switch...4025
          Function...4025
      MULTI-FUNCTION KNOB...4026
        Function...4026
        Modification of Multi-Function Lever...4027
          Required...4027
          Procedure...4028
      JOYSTICK STEERING KNOB...4029
        Function...4029
      KOMTRAX TERMINAL SYSTEM...4030
        KOMTRAX Terminal...4031
          Model TC301...4031
          Outline...4031
        Input and Output Signals...4032
      ENGINE STARTING CIRCUIT...4033
        Function...4034
        Operation...4034
      ENGINE STOPPING CIRCUIT...4035
        Operation...4035
      PREHEATING CIRCUIT...4036
        Outline...4036
        Operation...4036
      ENGINE POWER MODE SELECTOR CIRCUIT...4037
        Function...4037
        Operation...4037
      ENGINE OUTPUT DERATING FUNCTION...4038
      AUTOMATIC WARM-UP FUNCTION...4038
      PARKING BRAKE CIRCUIT...4039
        Operation...4039
        When ignition switch is turned OFF...4039
        When ignition switch is turned ON...4039
        When low oil pressure occurs on main brake (when emergency brake is applied)...4040
      SENSORS...4041
        Speed Sensor...4041
        Torque Converter Oil Temperature Sensor...4042
        Hydraulic Oil Temperature Sensor...4042
        Transmission Oil Temperature Sensor...4042
        Brake Oil Temperature Sensor...4042
        Work Equipment Pump Oil Pressure Sensor...4043
        Steering Pump Oil Pressure Sensor...4043
        Lift Cylinder Head Oil Pressure Sensor...4043
        Lift Cylinder Bottom Oil Pressure Sensor...4043
        Transmission Cutoff Oil Pressure Sensor...4044
        Coolant Lever Sensor...4045
        Fuel Level Sensor...4046
        Air Cleaner Clogging Sensor...4047
        Accelerator Pedal Sensor...4048
          Torque Values...4048
          Function...4048
          Accelerator signal...4048
          Idle Validation Signal...4048
        Water-In-Fuel Sensor...4049
        Boom Kickout Proximity Switch...4050
        Bucket Positioner Proximity Switch...4050
        Lift Arm Potentiometer...4051
    20 STANDARD VALUE TABLES...4052
      STANDARD VALUE TABLES...4053
        Service Value For Engine...4053
        Service Values For Chassis...4054
      POSTURE AND PERFORMANCE MEASUREMENTS...4056
        Machine Posture...4061
    30 TESTING AND ADJUSTING...4064
      TOOLS...4069
        Tools for Testing, Adjusting, and Troubleshooting...4069
      ENGINE COMPONENTS...4075
        Engine Speed...4075
          Measurement Conditions...4075
          Measure Engine Speed (Low and High Idle)...4075
          Measure Torque Converter Stall Speed...4075
          Measure Hydraulic Stall Speed...4076
          Measure Torque Converter Stall and Hydraulic Stall (Full Stall) Speed...4076
        Exhaust Gas Color...4077
          Special Tools Required...4077
          Measurement Condition...4077
          Using Handy Smoke Checker A1...4077
          Using Smoke Meter A2...4077
        Valve Clearance...4079
          Special Tools Required...4079
          Measurement Condition...4079
        Engine Compression...4081
          Special Tools Required...4081
          Measurement Condition...4081
        Blow-by Pressure...4085
          Special Tools Required...4085
          Measurement Conditions...4085
        Engine Oil Pressure...4087
          Special Tools Required...4087
          Measurement Condition...4087
        Intake Air (Boost) Pressure...4088
          Special Tool Required...4088
          Measurement Condition...4088
        Determining a Defective Cylinder...4090
          Procedures...4090
          Determining Cylinder Group...4090
          Isolating the Defective Cylinder...4090
      FUEL SYSTEM...4091
        Handling Fuel System Equipment...4091
          Precautions for Testing and Maintaining Fuel System...4091
          Precautions for Replacement of Fuel Filter Cartridge...4091
        Releasing Residual Pressure in Fuel System...4091
        Measuring Fuel Pressure...4092
          Special Tools Required...4092
          Measuring Pressure in Fuel Low-pressure Circuit...4092
          Measuring Pressure in Fuel Return Circuit...4093
          Measuring Fuel Negative-Pressure Circuit Pressure...4094
        Fuel Delivery, Return, and Leak Rate...4095
          Special Tools Required...4095
          Measuring Supply Pump Delivery...4095
          Measuring Return Rate from Supply Pump...4096
          Measuring Leakage from Pressure Limiter...4097
          Measuring Return Rate from Injector...4098
        Bleeding Air from Fuel Circuit...4099
        Testing Leakage in Fuel System...4100
        Handling Reduced Cylinder Mode Operation...4101
        Handling No-Injection Cranking Operation...4101
        Handling Controller Voltage Circuit...4101
      EXHAUST SYSTEM AND PIPING...4102
        Checking Muffler and Muffler Stack for Looseness and Damage...4102
        Checking Muffler Function...4102
        Checking Installed Condition of Cylinder Head and Manifolds...4102
        Checking Engine Piping for Damage and Looseness...4102
          Air Intake and Exhaust Systems...4102
          Cooling System...4102
          Fuel System...4102
      BELTS...4103
        Air Conditioner Compressor Belt...4103
          Testing...4103
          Adjusting...4103
        Alternator Belt...4104
          Replacing...4104
      DIRECTIONAL LEVER...4106
        Special Tool Required...4106
        Checking Operating Effort...4106
        Checking Stroke...4106
      POWER TRAIN OIL PRESSURES...4107
        Oil Pressure Measuring Points And Gauges...4109
          Special Tools Required...4109
        Measuring Transmission Hydraulic Operating Pressures...4110
          Transmission Main Relief Pressure...4110
          Torque Converter Relief Pressure (Inlet)...4111
          Torque Converter Outlet Pressure...4112
          Lockup Clutch Pressure (Lockup Clutch Specification)...4113
          F (Forward) Clutch Pressure...4114
          R (Reverse) Clutch Pressure...4115
          1st Clutch Pressure...4116
          2nd Clutch Pressure...4117
          3rd Clutch Pressure...4118
            9. After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition...4118
          4th Clutch Pressure...4119
          Lubrication Pressure...4120
        Adjusting Power Train Oil Pressures...4121
          Transmission Main Relief Valve...4121
      TRANSMISSION...4122
        Speed Sensor...4122
        Flushing Transmission System...4123
          Torque Converter, Transmission, and Hydraulic Circuit...4123
        Moving the Machine if Transmission Valve Fails...4125
          Moving the Machine...4126
          Special Tool Required...4126
      STEERING SYSTEM...4129
        Steering Stop Valve...4129
          Testing...4129
          Adjusting...4129
        Steering Wheel...4131
          Special Tool Required...4131
          Measuring Play in Steering Wheel...4131
          Measuring Operating Effort of Steering Wheel...4131
          Measuring Operating Time of Steering Wheel...4132
        Steering Oil Pressure...4133
          Special Tools Required...4133
          Measuring Steering Relief Pressure...4133
          Measuring Steering Pilot Circuit Pressure...4134
          Adjusting Steering Relief Pressure...4135
          Adjusting Steering Control Circuit Pressure...4135
        Bleeding Air from Steering Circuit...4136
          Bleeding Air from Steering Pump...4136
          Bleeding Air from Steering Cylinder Circuit...4136
        Steering Column Lock Lever...4137
      HYDRAULIC DRIVE FAN...4139
        Special Tools Required...4139
        Measurement Conditions:...4139
        Measuring Fan Speed...4139
        Measuring Fan Drive Oil Pressure...4140
        Bleeding Air from Hydraulic Drive Fan Circuit...4141
          Special Tools Required...4141
          Bleeding Air From Fan Pump...4141
          Bleeding Air from Fan Motor Circuit...4142
      WHEEL BRAKE SYSTEM...4143
        Measuring Brake Performance...4144
          Measurement Conditions...4144
        Accumulator Charge...4145
          Special Tools Required...4145
          Measurement Conditions...4145
          Measuring...4145
          Adjusting...4146
        Measuring Brake Oil Pressure...4147
          Special Tools Required...4147
          Brake Test Kit S...4148
        Testing Wear of Wheel Brake Disc...4149
          Special Tools Required...4149
        Bleeding Air from Brake Circuit...4150
        Releasing Residual Pressure in Brake Accumulator Circuit...4150
      PARKING BRAKE SYSTEM...4151
        Testing Parking Brake Performance...4151
          Measurement Conditions...4151
          Measuring Parking Brake Oil Pressure...4153
            Special Tools Required...4153
            Measurement Conditions...4153
          Checking Wear of Parking Brake Disc...4155
            Special Tools Required...4155
          Releasing Parking Brake Manually...4156
      WORK EQUIPMENT SYSTEM...4157
        Work Equipment Control Levers...4157
          Special Tools Required...4157
          Measurement Conditions...4157
          Measuring Operating Effort...4157
          Measuring Stroke...4157
        PPC Oil Pressure...4158
          Special Tools Required...4158
          Measurement Condition...4158
          Measuring PPC Valve Basic Pressure...4158
          Measuring PPC Valve Output Pressure...4159
          Replacing PPC Relief Valve...4160
        Work Equipment Hydraulic Pressure...4161
          Special Tools Required...4161
          Measurement Condition...4161
          Combination of Actuator And Valve...4161
          Preparation Work...4161
          Measuring Work Equipment Relief Pressure...4162
          Measuring Unload Pressure...4163
          Measuring Work Equipment LS Differential Pressure...4164
          Adjusting Work Equipment Relief Pressure...4165
          Adjusting LS Differential Pressure...4165
        Bleeding Air from Work Equipment Circuit...4166
          From Work Equipment Pump (Piston Pump)...4166
          From Hydraulic Cylinder...4166
        Releasing Residual Pressure in Work Equipment Circuit...4167
          From Circuit Between Hydraulic Cylinders and Control Valve...4167
          From ECSS (Travel Damper) Circuit...4167
        Work Equipment Positioners...4168
          Bucket Positioner...4168
            Measurement Conditions...4168
            Testing...4168
            Adjusting Clearance...4168
            Adjusting Mounting Position (Stopping Position)...4168
          Boom Kickout...4169
            Testing...4169
            Adjusting...4169
        Proximity Switch Operation Pilot Lamp...4170
      ELECTRICAL SYSTEM TROUBLESHOOTING...4171
        Procedure for Testing Diodes...4171
          When Using Digital Type Circuit Tester...4171
          When Using Analog Type Circuit Tester...4172
        Preparation for Troubleshooting Electric System...4173
          Machine Monitor...4173
          Transmission Controller...4174
          Work Equipment Controller (if equipped)...4175
          KOMTRAX Terminal...4175
          Sensors...4176
          Boost Pressure and Temperature Sensor (BOOST PRESS & IMT)...4176
          Supply Pump IMV Solenoid (FUEL REGULATOR)...4176
          Common Rail Pressure Sensor (FUEL RAIL PRESS)...4177
          Engine Coolant Temperature Sensor (COOLANT TEMP)...4177
      KOMTRAX TERMINAL SYSTEM...4178
        Terminal Installed at Plant Before Shipment...4178
        Terminal Retrofitted Machine After Shipment...4178
        Starting Operation...4178
          Station Opening Check in Machine Side...4178
          Application for the Start of Use...4181
            Request for Orbcomm Terminal Activation Form...4182
        Komtrax Terminal Lamps...4183
          Checking Antennas...4184
          Checking Terminal LED Displays...4184
          Display Contents of 7-segment And Dot For CPU...4185
      MACHINE MONITOR SYSTEM...4186
        Adjusting Machine Monitor...4186
        Adjusting for Replaced, Reassembled, or Added Sensor/Controller...4187
        Adjustment for User’s Needs...4188
        Special Functions of Machine Monitor (EMMS)...4189
          Normal and Special Functions of Machine Monitor...4189
        Functions and Flow of Service Mode...4190
        Operator Mode...4193
          Service Meter/Clock Display Function (1)...4193
          Load Meter Function (2) (if equipped)...4193
          Odometer Display Function (3)...4193
          Maintenance Monitoring Function (4)...4194
            1. Filter, oil replacement time display (automatic display)...4194
            2. Resetting replacement time (selection menu)...4194
          Telephone Number Input Function (5)...4194
          Language Selection Function (6)...4194
          Monitor Brightness Adjustment Function (7)...4194
          Time Adjustment Function (8)...4195
          Travel Speed/Engine Speed Display Selecting Function (9)...4195
          Travel Speed/Engine Speed Display/Non-Display Selecting Function (10)...4195
          Action Code Display Function (11)...4196
            Action Codes and Actions Alerted to Operator...4196
          Failure Code Display Function (12)...4196
        Service Mode...4198
          Switching to Service Mode and Screen Display (1)...4198
          Electrical System Fault History Display Function (ELECTRIC FAULT) (2)...4200
          Mechanical System Fault History Display Function (MACHINE FAULT) (3)...4202
          Real-Time Monitoring Function (REAL-TIME MONITOR) (4)...4203
          Real-Time Monitoring Code Tables...4206
            Monitor Panel (Machine Monitor System)...4206
            MON (Mechanical Monitor System)...4211
            Transmission (Transmission Controller System)...4213
            TM: Detailed Data for Input and Output Signals (Transmission Controller System)...4219
          WRK (Work Equipment Controller Display)...4223
          ENG (Engine Controller System)...4231
          Engine Reduced-Cylinder Function (CYLINDER CUT-OUT) (5)...4233
          No-Injection Cranking Function (6)...4234
          Adjustment Function (TUNING) (7)...4235
            Adjustment Function...4235
            Adjustment of Transmission ECMV Current (7-1)...4236
            Setting of Transmission Initial Learning (7-2)...4240
            Adjustment of Transmission L Mode Gearshift Point (7-3)...4243
            Adjustment of Lift Arm Angle Sensor (Raise) (for EPC lever) (7-4)...4246
            Adjustment of Lift Arm Raise Lever and Variations in the Dead Zone of EPC (7-5)...4246
            Adjustment of Lift Arm Lower (Float) Lever and Variations in the Dead Zone of EPC (7-6)...4246
            Adjustment of Bucket Tilt Lever and Variations in the Dead Zone of EPC (7-7)...4246
            Adjustment of Bucket Dump EPC Starting Current (7-8)...4247
            Adjustment of 3-spool Valve EPC Cylinder Extraction Lever and Variations in the Dead Zone of EPC (7-9)...4247
            Adjustment of 3-spool valve EPC Cylinder Retraction Lever and Variations in the Dead Zone of EPC (7-10)...4247
            Adjustment of Joystick Steering Right Lever and Variations at EPC Starting Point (7-11)...4247
            Adjustment of Joystick Steering Left Lever and Variations at EPC Starting Point (7-12)...4247
            Modification of Lift Arm Lever Pattern (7-13)...4247
            Modification of Bucket Lever Pattern (7-14)...4247
            Adjustment of Lift Arm Lower Stop Modulation (7-15)...4247
            Adjustment of Pump Cutoff Pressure in Lift Arm Raise (7-16)...4247
            Adjustment of Lift Arm Angle Sensor (Raise) (7-17)...4247
            Adjustment of Lift Arm Angle Sensor (Lower) (7-18)...4248
            Adjustment of 2-stage Low Idle Throttle Position (7-19)...4250
            Adjustment of Interval of Fan Automatic Reverse Operation (Automatic Reverse Fan) (7-20)...4250
            Adjustment of Continuance of Fan Automatic Reverse Operation (Automatic Reverse Fan) (7-21)...4251
          Maintenance Monitoring Function (8)...4252
            Changing Maintenance Interval Time (8-1)...4252
            Selecting Enabling or Disabling Timer by Item (8-2)...4254
            Changing Set Default Value (8-3)...4255
            Selecting between Timer Stop for All Items and Enable by Item (8-4)...4256
          Operating Information Display Function (OPERATION INFO) (9)...4258
            Selecting Menu...4258
          Optional Device Selecting Function (10)...4261
            Optional Component Setting table...4261
            Change or Settlement for BOOM TYPE OPTION SELECT (10-1)...4263
            Option Setting/Not Setting Selection (10-2)...4264
            Setting Tire Deflection Option (10-3)...4264
            Storing Option Selection (10-4)...4264
          Machine Serial Number Input Function (11)...4265
          Model Select Function (12)...4265
            Implementing the Model Change...4265
            Storing Model Change (12-2)...4266
          Initialize Function (13)...4266
      PM-CLINIC INSPECTION TABLE...4267
    40 TROUBLESHOOTING...4272
      POINTS TO REMEMBER WHEN TROUBLESHOOTING...4288
      SEQUENCE OF EVENTS IN TROUBLESHOOTING...4290
      PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...4291
        Precautions when Handling Electrical Equipment...4291
        Handling Electronic Control Unit...4296
        Points to Remember when Troubleshooting Electrical Circuits...4297
      ELECTRIC WIRE CODE...4298
        Classification by Thickness...4298
        Classification by Color and Code...4298
        How to Read Electric Wire Code...4299
          Type, Symbol, and Material...4299
          Dimensions...4300
      HANDLING HYDRAULIC EQUIPMENT...4301
      CHECKS BEFORE TROUBLESHOOTING...4303
        Categories and Method of Using Troubleshooting Charts...4304
        Troubleshooting Individual Electrical Circuits...4305
          Chart Use...4307
          Chart Tips...4307
        Troubleshooting Individual Hydraulic Circuits...4308
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...4310
        X-Type Connectors...4310
        SWP-Type Connectors...4312
        M-Type Connectors...4314
        S-Type Connectors...4316
        MIC-Type Connectors...4318
        AMP040-Type Connectors...4320
        AMP070-Type Connectors...4322
        AMP Connector...4324
        L-Type Connector...4324
        PA-Type Connector...4325
        Bendix (MS) Connector...4325
        KES1 (Automobile) Connectors...4326
        F-Type Connector...4327
        Connectors for Relay (Socket-Type)...4328
        HD30 Series Connectors...4329
        DT Series Connectors...4335
        DTM Series Connectors...4337
        DTHD Series Connectors...4337
        DTP Series Connectors...4338
        DRC26 Series Connectors...4339
        DRC12, 16 Series Connectors...4341
        AMP Connectors for Pump Controller (CH700)...4342
        BOSCH Connectors for Engine...4343
        SUMITOMO Connectors for Engine...4344
        CANNON Connector for Engine...4345
        AMP Connectors for Engine...4346
        FRAMATOME Connectors for Engine...4347
        PACKARD Connectors for Engine...4349
        DT Series Connectors for Engine...4350
      T-BRANCH BOX and T-BRANCH ADAPTER TABLE...4351
      MODE CHART...4356
      INFORMATION CONTAINED IN TESTING PROCEDURES...4359
      TROUBLESHOOTING BY FAILURE CODE...4361
        Failure Code Table...4361
      FUSE BOX AND SLOW-BLOW FUSES...4372
        Connection Table...4372
          Fuse Box 1...4372
          Fuse Box 2...4373
          Slow-Blow Fuses...4373
      FAILURE CODES...4375
        1500L0...4376
          TORQFLOW Transmission: Double Meshing...4376
        15SAL1...4377
          ECMV F Clutch: When Command Current is OFF, Fill Signal is ON...4377
        15SALH...4379
          ECMV F Clutch: When Command Current is ON, Fill Signal is OFF...4379
        15SBL1...4381
          ECMV R Clutch: When Command Current is OFF, Fill Signal is ON...4381
        15SBLH...4383
          ECMV R Clutch: When Command Current is ON, Fill Signal is OFF...4383
        15SEL1...4385
          ECMV 1st Clutch: When Command Current is OFF, Fill Signal is ON...4385
        15SELH...4387
          ECMV 1st Clutch: When Command Current is ON, Fill Signal is OFF...4387
        15SFL1...4389
          ECMV 2nd Clutch: When Command Current is OFF, FIll Signal is ON...4389
        15SFLH...4391
          ECMV 2nd Clutch: When Command Current is ON, Fill Signal is OFF...4391
        15SGL1...4393
          ECMV 3rd Clutch: When Command Current is OFF, Fill Signal is ON...4393
        15GLH...4395
          ECMV 3rd Clutch: When Command Current is ON, Fill Signal is OFF...4395
        15SHL1...4397
          ECMV 4th Clutch: When Command Current is OFF, Fill Signal is ON...4397
        15SHLH...4399
          ECMV 4th Clutch: When Command Current is ON, Fill Signal is OFF...4399
        2F00MA...4401
          Parking Brake: Malfunction...4401
        2G43ZG...4403
          Rear Accumulator: Low Oil Pressure...4403
        44K0L4...4405
          Bucket Positioner: ON/OFF Signals Disagree...4405
        AA1ANX...4409
          Air Cleaner: Clogging...4409
        AB00L6...4411
          Alternator: Signal Disagrees with Operating State of Engine...4411
        AB00MA...4413
          Alternator: Malfunction...4413
        B@BAZG...4415
          Engine: Rotation Derating by Low Engine Oil Pressure...4415
        B@BAZK...4416
          Engine Oil: Low Level...4416
        B@BCNS...4417
          Engine Coolant: Overheating...4417
        B@BCZK...4419
          Engine Coolant: Low Level...4419
        B@BEBF...4421
          Water in Fuel Error...4421
        B@C7NS...4423
          Brake Oil: Overheating...4423
        b@CENS...4425
          Torque Converter Oil: Overheating...4425
        B@CENS...4427
          Torque Converter Oil: Overheating...4427
        B@HANS...4429
          Hydraulic Oil: Overheating...4429
        CA111...4431
          Abnormality in Engine Controller...4431
        CA115...4432
          Engine Ne or Bkup Speed Sensor Error...4432
        CA122...4433
          Charge Pressure Sensor High Error...4433
        CA123...4435
          Charge Pressure Sensor Low Error...4435
        CA131...4437
          Throttle Sensor High Error...4437
        CA132...4439
          Throttle Sensor Low Error...4439
        CA144...4441
          Coolant Temperature Sensor High Error...4441
        CA145...4443
          Coolant Temperature Sensor Low Error...4443
        CA153...4445
          Charge Temperature Sensor High Error...4445
        CA154...4447
          Charge Temperature Sensor Low Error...4447
        CA155...4449
          Derating of Speed by Abnormally High Charge Temperature...4449
        CA187...4451
          Sensor Power Supply 2 Low Error...4451
        CA221...4453
          Atmospheric Pressure Sensor High Error...4453
        CA222...4455
          Atmospheric Pressure Sensor Low Error...4455
        CA227...4457
          Sensor Power Supply 2 High Error...4457
        CA234...4459
          Engine Overspeed...4459
        CA238...4460
          Ne Speed Sensor Power Supply Error...4460
        CA271...4461
          IMV/PCV1 Short Circuit...4461
        CA272...4463
          IMV/PCV1 Disconnection...4463
        CA322...4465
          Injector #1 Open/Short Error...4465
        CA323...4467
          Injector #5 Open/Short Error...4467
        CA324...4469
          Injector #3 Open/Short Error...4469
        CA325...4471
          Injector #6 Open/Short Error...4471
        CA331...4473
          Injector #2 Open/Short Error...4473
        CA332...4475
          Injector #4 Open/Short Error...4475
        CA342...4477
          Calibration Code Inconsistency...4477
        CA351...4479
          Injectors Drive Circuit Error...4479
        CA352...4481
          Sensor Power Supply 1 Low Error...4481
        CA386...4483
          Sensor Power Supply 1 High Error...4483
        CA428...4485
          Abnormally High Level in Water Sensor...4485
        CA429...4487
          Abnormally Low Level in Water Sensor...4487
        CA431...4489
          Idle Validation Switch Error...4489
        CA432...4493
          Idle Validation Action Error...4493
        CA435...4495
          Engine Oil Pressure Switch Error...4495
        CA441...4497
          Battery Voltage Low Error...4497
        CA442...4501
          Battery Voltage High Error...4501
        CA449...4503
          Common Rail Pressure High Error 2...4503
        CA451...4507
          Common Rail Pressure Sensor High Error...4507
        CA452...4509
          Common Rail Pressure Sensor Low Error...4509
        CA488...4511
          Derating of Torque by Abnormally High Charge Temperature...4511
        CA553...4512
          Common Rail Pressure High Error 1...4512
        CA559...4513
          Supply Pump Pressure Very Low Error 1...4513
        CA689...4515
          Engine Ne Speed Sensor Error...4515
        CA731...4517
          Engine Bkup Speed Sensor Phase Error...4517
        CA757...4518
          All Continuous Data Lost Error...4518
        CA778...4521
          Engine Bkup Speed Sensor Error...4521
        CA1633...4523
          KOMNET Datalink Timeout Error...4523
        CA2185...4525
          Throttle Sensor Power Supply Voltage High Error...4525
        CA2186...4526
          Throttle Sensor Power Supply Voltage Low Error...4526
        CA2249...4527
          Supply Pump Pressure Very Low Error 2...4527
        CA2311...4529
          Abnormality in IMV Solenoid...4529
        CA2555...4531
          Intake Heater Relay Disconnection Error...4531
        CA2556...4533
          Intake Heater Relay Short Circuit Error...4533
        D150KA...4535
          Emergency Steering Relay: Disconnection...4535
        D150KB...4537
          Emergency Steering Relay: Short Circuit...4537
        D150KY...4539
          Emergency Steering Relay: Short Circuit with Power Supply Line...4539
        D160KA...4541
          Backup Lamp Relay: Disconnection...4541
        D160KB...4543
          Backup Lamp Relay: Short Circuit...4543
        D191KA...4545
          Joystick Steering Neutral Safety Relay: Disconnection...4545
        D191KB...4547
          Joystick Steering Neutral Safety Relay: Short Circuit...4547
        D191KY...4549
          Joystick Steering Neutral Safety Relay: Short Circuit with Power Supply Line...4549
        D192KA...4551
          ECSS Solenoid: Disconnection...4551
        D192KB...4553
          ECSS Solenoid: Short Circuit...4553
        D192KY...4555
          ECSS Solenoid Relay: Short Circuit with Power Supply Line...4555
        D193KA...4557
          Joystick Steering Solenoid Cut Relay: Disconnection...4557
        D193KB...4559
          Joystick Steering Solenoid Cut Relay: Short Circuit...4559
        D193KY...4561
          Joystick Steering Solenoid Cut Relay: Short Circuit with Power Supply Line...4561
        D5ZHKA...4563
          Terminal C Signal: Disconnection...4563
        D5ZHKB...4567
          Terminal C Signal: Short Circuit...4567
        D5ZHKZ...4571
          Terminal C Signal: Disconnection or Short Circuit...4571
        D5ZHL6...4575
          Terminal C Signal: Signal Does Not Match Engine Running or Stopped State...4575
        DA80L4...4579
          Auto-Grease Controller: ON/OFF Signals Disagree...4579
        DAF3KK...4581
          Machine Monitor: Low Source Voltage (input)...4581
        DAF5KP...4583
          Machine Monitor: Low Output Voltage...4583
        DAFRKR...4587
          Machine Monitor: CAN Defective Communication...4587
        DAQ0KK...4591
          Transmission Controller: Low Source Voltage...4591
        DAQ0KT...4593
          Transmission Controller: Abnormality in Controller...4593
        DAQ2KK...4595
          Transmission Controller Load Power Supply Line: Low Source Voltage (input)...4595
        DAQ9KQ...4597
          Transmission Controller: Disagreement of Model Selection Signals...4597
        DAQRKR...4599
          CAN Communication with Transmission Controller: Defective Communication...4599
        DAQRMA...4602
          Transmission Controller Option Setting: Malfunction...4602
        DB2RKR...4603
          CAN Communication with Engine Controller: Defective Communication...4603
        DB90KK...4607
          Work Equipment Controller: Low Source Voltage (input)...4607
        DB90KT...4609
          Work Equipment Controller: Abnormality in Controller...4609
        DB92KK...4611
          Work Equipment Controller Load Power Supply Line: Low Source Voltage (input)...4611
        DD95KX...4613
          Work Equipment Controller Power Supply Output: Out-of-Input Signal Range...4613
        DB99KQ...4616
          Work Equipment Controller: Disagreement in Model Selection Signals...4616
        DB9RKR...4617
          CAB Communication with Work Equipment Controller: Defective Communication...4617
        DB9RMA...4620
          Work Equipment Controller Option Setting: Malfunction...4620
        DB9RMC...4621
          CAN Communication: Defective Operation...4621
        DD15LD...4625
          Switch (Panel Switch 1 n): Switch is Pressed for Long Time...4625
        DD16LD...4627
          Switch (Panel Switch 2 ‡): Switch is Pressed for Long Time...4627
        DD17LD...4629
          Switch (Panel Switch 3 <): Switch is Pressed for Long Time...4629
        DD18LD...4631
          Switch (Panel Switch 4 >): Switch is Pressed for Long Time...4631
        DD1ALD...4633
          Remote Positioner Raise/Lower Set Switch (raise): Switch is Pressed for Long Time...4633
        DD1BLD...4635
          Remote Positioner Raise/Lower Set Switch (lower): Switch is Pressed for Long Time...4635
        DD1CLD...4637
          Load Meter Subtotal Switch: Switch is Pressed for Long Time...4637
        DD1FLD...4639
          Load Meter Mode Selector Switch (A/B): Switch is Pressed for Long Time...4639
        DD1GLD...4641
          Load Meter Mode Selector Switch (+/-): Switch is Pressed for Long Time...4641
        DD1HLD...4643
          Load Meter Display Selector Switch: Switch is Pressed for Long Time...4643
        DD1NLD...4645
          Fan Reverse Switch: Switch is Pressed for Long Time...4645
        DD1NL4...4647
          Fan Automatic Reverse Switch: Switch is Pressed for Long Time...4647
        DDB6L4...4649
          Parking Brake Switch (Neutralizer): ON/OFF Signals Disagree...4649
        DDE5MA...4653
          Emergency Steering Drive Switch: Malfunction...4653
        DDK3KA...4655
          Right FNR Switch: Disconnection...4655
        DDK4KA...4658
          Joystick Steering FNR Switch: Disconnection...4658
        DDK5L4...4661
          Joystick Steering Shift UP/DOWN Switch: ON/OFF Signals Disagree...4661
        DDK6KA...4663
          FNR Lever Switch: Disconnection...4663
        DDK6KB...4666
          FNR Lever Switch: Short Circuit...4666
        DDS5KA...4669
          Steering Pressure Switch: Disconnected...4669
        DDS5KB...4671
          Steering Pressure Switch: Grounded...4671
        DDT0L4...4673
          Shift Mode Selector Switch: ON/OFF Signals Disagree...4673
        DDT4LD...4675
          Transmission Cutoff Set Switch: Switch is Pressed for Long Time...4675
        DDW9LD...4677
          Kickdown Switch: Switch is Pressed for Long Time...4677
        DDWLLD...4679
          Hold Switch: Switch is Pressed Down for Long Time...4679
        DDY0LD...4681
          Load Meter Cancel Switch: Switch is Pressed for Long Time...4681
        DF10KA...4683
          Transmission Shift Lever Switch: Disconnected...4683
        DF10KB...4687
          Transmission Shift Lever Switch: Short Circuit...4687
        DGF1KA...4691
          Transmission Oil Temperature Sensor: Disconnected...4691
        DGF1KB...4693
          Transmission Oil Temperature Sensor: Short Circuit...4693
        DGH2KX...4695
          Hydraulic Oil Temperature Sensor: Out-of-Input Signal Range...4695
        DGR2KA...4697
          Rear Brake Oil Temperature Sensor: Disconnected...4697
        DGR2KX...4699
          Rear Brake Oil Pressure Sensor: Out-of-Input Signal Range...4699
        DGT1KX...4701
          Torque Converter Oil Temperature Sensor: Out-of-Input Signal Range...4701
        DH21KA...4703
          Loader Pump Pressure Sensor: Disconnection...4703
        DH21KB...4705
          Loader Pump Pressure Sensor: Power Supply Line Short...4705
        DHPCKX...4707
          Lift Arm Cylinder Bottom Pressure Sensor: Out-of-Input Signal Range...4707
        DHPDKX...4709
          Lift Arm Cylinder Head Pressure Sensor: Out-of-Input Signal Range...4709
        DHT1KX...4711
          Transmission Cutoff Pressure Sensor: Out-of-Input Signal...4711
        DHT8KA...4713
          Steering Pump Pressure Sensor: Disconnection...4713
        DHT8KB...4715
          Steering Pump Pressure Sensor: Short Circuit...4715
        DK59KA...4717
          Lift Arm EPC Lever Potentiometer (Main): Disconnection...4717
        DK59KY...4720
          Lift Arm EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line...4720
        DK59L8...4724
          Lift Arm EPC Lever Potentiometer (Main): Analog Signals Disagree...4724
        DK5AKA...4728
          Lift Arm EPC Lever Potentiometer (Sub): Disconnection...4728
        DK5AKY...4731
          Lift Arm EPC Lever Potentiometer (Sub): Short Circuit with Power Supply LIne...4731
        DK5BKA...4734
          Bucket EPC Lever Potentiometer (Main): Disconnection...4734
        DK5BKY...4737
          Bucket EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line...4737
        DK5BL8...4740
          Bucket EPC Lever Potentiometer (Main): Analog Signals Disagree...4740
        DK5CKA...4743
          Bucket EPC Lever Potentiometer (Sub): Disconnection...4743
        DK5CKY...4746
          Bucket EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line...4746
        DK5FKA...4749
          Joystick Steering EPC Lever Potentiometer (Main): Disconnection...4749
        DK5FKY...4752
          Joystick Steering EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line...4752
        DK5GKA...4755
          Joystick Steering EPC Lever Potentiometer (Sub): Disconnection...4755
        DK5GKY...4758
          Joystick Steering EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line...4758
        DK5FL8...4761
          Joystick Steering EPC Lever Potentiometer (Main): Analog Signals Disagree...4761
        DKA0KA...4764
          Lift Arm Angle Sensor: Disconnection...4764
        DKA0KY...4768
          Lift Arm Angle Sensor: Short Circuit with Power Supply Line...4768
        DKA0L0...4770
          Lift Arm Angle Sensor: Double Meshing...4770
        DLT3KA...4772
          Transmission Output Shaft Speed Sensor: Disconnection...4772
        DLT3LC...4774
          Transmission Output Shaft Speed Sensor: Out-of-Input Signal Range...4774
        DT20KB...4776
          Transmission Cutoff Indicator Lamp: Short Circuit...4776
        DUM1KB...4778
          Remote Positioner Raise Set Indicator Lamp: Short Circuit...4778
        DUM2KB...4780
          Remote Positioner Lower Set Indicator Lamp: Short Circuit...4780
        DV00KB...4782
          Alarm Buzzer: Short Circuit...4782
        DW4PKA...4784
          Lift Arm Raise EPC Solenoid: Disconnection...4784
        DW4PKB...4786
          Lift Arm Raise EPC Solenoid: Short Circuit...4786
        DW4PKY...4788
          Lift Arm Raise EPC Solenoid: Short Circuit with Power Supply Line...4788
        DW4QKA...4790
          Lift Arm Lower EPC Solenoid: Disconnection...4790
        DW4QKB...4792
          Lift Arm Lower EPC Solenoid: Short Circuit...4792
        DW4QKY...4794
          Lift Arm Lower EPC Solenoid: Short Circuit with Power Supply Line...4794
        DW4RKA...4796
          Bucket Tilt EPC Solenoid: Disconnection...4796
        DW4RKB...4798
          Bucket Tilt EPC Solenoid: Short Circuit...4798
        DW4RKY...4800
          Bucket Tilt EPC Solenoid: Short Circuit with Power Supply Line...4800
        DW4SKA...4802
          Buck Dump EPC Solenoid: Disconnection...4802
        DW4SKB...4804
          Bucket Dump EPC Solenoid: Short Circuit...4804
        DW4SKY...4806
          Bucket Dump EPC Solenoid: Short Circuit with Power Supply Line...4806
        DW7BKA...4808
          Fan Reverse Solenoid: Disconnection...4808
        DW7BKB...4810
          Fan Reverse Solenoid: Short Circuit...4810
        DW7BKY...4812
          Fan Reverse Solenoid: Short Circuit with Power Supply Line...4812
        DWM1KA...4814
          Work Equipment Neutral Lock Solenoid: Disconnection...4814
        DWM1KB...4816
          Work Equipment Neutral Lock Solenoid: Short Circuit...4816
        DWM1KY...4818
          Work Equipment Neutral Lock Solenoid: Short Circuit with Power Supply Line...4818
        DWN6KA...4820
          Lift Arm Raise Magnet Detent Solenoid: Disconnection...4820
        DWN6KB...4822
          Lift Arm Raise Magnet Detent Solenoid: Short Circuit...4822
        DWN6KY...4824
          Lift Arm Raise Magnet Detent Solenoid: Short Circuit with Power Supply Line...4824
        DWN7KA...4826
          Lift Arm Float Magnet Detent Solenoid: Disconnection...4826
        DWN7KB...4828
          Lift Arm Float Magnet Detent Solenoid: Short Circuit...4828
        DWN7KY...4830
          Lift Arm Float Magnet Detent Solenoid: Short Circuit with Power Supply Line...4830
        DWN8KA...4832
          Bucket Tilt Magnet Detent Solenoid: Disconnection...4832
        DWN8KB...4834
          Bucket Tilt Magnet Detent Solenoid: Short Circuit...4834
        DWN8KY...4836
          Bucket Tilt Magnet Detent Solenoid: Shorted with the Power Source...4836
        DX16KA...4838
          Fan Pump EPC Solenoid: Disconnection...4838
        DX16KB...4840
          Fan Pump EPC Solenoid: Short Circuit...4840
        DX16KY...4842
          Fan Pump EPC Solenoid: Short Circuit with Power Supply Line...4842
        DXA1KA...4844
          Loader Pump EPC Solenoid: Disconnection...4844
        DXH1KA...4846
          Lockup ECMV Solenoid: Disconnection...4846
        DXH1KB...4848
          Lockup ECMV Solenoid: Short Circuit...4848
        DXH1KY...4850
          Lockup ECMV Solenoid: Short Circuit with Power Supply Line...4850
        DXH4KA...4852
          1st Clutch ECMV Solenoid: Disconnection...4852
        DXH4KB...4854
          1st Clutch ECMV Solenoid: Short Circuit...4854
        DXH4KY...4856
          1st Clutch ECMV Solenoid: Short Circuit with Power Supply Line...4856
        DXH5KA...4858
          2nd Clutch ECMV Solenoid: Disconnection...4858
        DXH5KB...4860
          2nd Clutch ECMV Solenoid: Short Circuit...4860
        DXH5KY...4862
          2nd Clutch ECMV Solenoid: Short Circuit with Power Supply Line...4862
        DXH6KA...4864
          3rd Clutch ECMV Solenoid: Disconnection...4864
        DXH6KB...4866
          3rd Clutch ECMV Solenoid: Short Circuit...4866
        DXH6KY...4868
          3rd Clutch ECMV Solenoid: Short Circuit with Power Supply Line...4868
        DXH7KA...4870
          R Clutch ECMV Solenoid: Disconnection...4870
        DXH7KB...4872
          R Clutch ECMV Solenoid: Short Circuit...4872
        DXH7KY...4874
          R Clutch ECMV Solenoid: Short Circuit with Power Supply Line...4874
        DXH8KA...4876
          F Clutch ECMV Solenoid: Disconnection...4876
        DXH8KB...4878
          F Clutch ECMV Solenoid: Short Circuit...4878
        DXH8KY...4880
          F Clutch ECMV Solenoid: Short Circuit with Power Supply Line...4880
        DXHHKA...4882
          4th Clutch ECMV Solenoid: Disconnection...4882
        DXHHKB...4884
          4th Clutch ECMV Solenoid: Short Circuit...4884
        DXHHKY...4886
          4th Clutch ECMV Solenoid: Short Circuit with Power Supply Line...4886
        DXHLKA...4888
          Joystick Steering Right EPC Solenoid: Disconnection...4888
        DXHLKB...4890
          Joystick Steering Right EPC Solenoid: Short Circuit...4890
        DXHLKY...4892
          Joystick Steering Right EPC Solenoid: Short Circuit with Power Supply Line...4892
        DXHMKA...4894
          Joystick Steering Left EPC Solenoid: Disconnection...4894
        DXHMKB...4896
          Joystick Steering Left EPC Solenoid: Short Circuit...4896
        DXHMKY...4898
          Joystick Steering Left EPC Solenoid: Short Circuit with Power Supply Line...4898
        DY30MA...4900
          Motor-Driven Emergency Steering Pump Failure (during Operation of machine)...4900
        DY30MC...4903
          Motor-Driven Emergency Steering Pump Failure (Malfunction in Manual Mode)...4903
      TROUBLESHOOTING: E-MODE...4906
        E-1...4908
          Engine Does Not Start...4908
        E-2...4914
          Wiper Does Not Operate...4914
        E-3...4918
          Windshield Washer Does Not Operate...4918
        E-4...4922
          Headlamp, Clearance Lamp, Tail Lamp, and License Lamp Do Not Light Up or Go Off...4922
        E-5...4930
          Working Lamp Does Not Light Up or Go Off...4930
        E-6...4936
          Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off...4936
        E-7...4943
          Brake Lamp Does Not Light or It Keeps Lighting Up...4943
        E-8...4946
          Backup Lamp Does Not Light or It Keeps Lighting Up...4946
        E-9...4949
          Backup Buzzer Does Not Sound or It Keeps Sounding...4949
        E-10...4952
          Horn Does Not Sound or It Keeps Sounding...4952
        E-11...4955
          Alarm Buzzer Does Not Sound or It Keeps Sounding...4955
        E-12...4957
          Air Conditioner Does Not Operate or Stop...4957
        E-13...4961
          KOMTRAX System Does Not Work Properly...4961
            Indicator Lamps of KOMTRAX Terminal...4963
        E-14...4965
          When Kickdown Switch is Turned On, Kickdown Operation Does Not Start...4965
        E-15...4967
          When Hold Switch is Pressed, Holding Operation Does Not Start...4967
        E-16...4969
          Transmission Kept in Neutral or Brake Drags when Directional Lever is Operated While Parking Brake is Applied...4969
        E-17...4971
          Transmission Cutoff Mode Cannot Be Set or Reset...4971
        E-18...4973
          Transmission Cutoff Set Cannot be Reset...4973
        E-19...4975
          FN Switch Mode Cannot Be Set or Reset...4975
        E-20...4977
          Fan Reverse Function Cannot Be Used or Reset...4977
        E-21...4979
          Discharge from Loader Pump Does Not Rise from Minimum Level...4979
        E-22...4981
          ECSS Function Cannot Be Used or Reset...4981
        E-23...4983
          When Parking Brake is Turned On, Parking Brake Indicator Lamp Does Not Light Up...4983
        E-24...4987
          When Emergency Brake Operates, Brake Oil Pressure Caution Lamp Does Not Operate...4987
        E-25...4989
          Air Cleaner Clogging Indicator Lamp Does Not Light Up...4989
        E-26...4991
          Radiator Coolant Level Caution Lamp Does Not Light Up...4991
        E-27...4993
          Hydraulic Oil Temperature Gauge Does Not Rise and Hydraulic Oil Temperature Caution Lamp Does Not Light Up...4993
        E-28...4995
          Torque Converter Oil Temperature Gauge Does Not Rise and Torque Converter Oil Temperature Caution Lamp Does Not Light Up...4995
        E-29...4997
          Steering Oil Pressure Caution Lamp Does Not Light Up...4997
        E-30...4999
          Abnormality in Switch (n) (Panel Switch 1) Input...4999
        E-31...5001
          Abnormality in Switch (‡) (Panel Switch 2) Input...5001
        E-32...5003
          Abnormality in Switch (<) (Panel Switch 3) Input...5003
        E-33...5005
          Abnormality in Switch (>) (Panel Switch 4) Input...5005
        Troubleshooting Electrical System...4906
          Information in Troubleshooting Table...4906
      TROUBLESHOOTING: H-MODE...5007
        H-1...5013
          Machine Does Not Start...5013
        H-2...5015
          Torque Converter Lockup is Not Switched OFF (Engine Stalls)...5015
        H-3...5016
          Torque Converter Lockup is Not Switched ON...5016
        H-4...5017
          Travel Speed is Slow, Thrusting Force is Weak, Uphill Traveling Power is Weak, Gear is Not Shifted...5017
        H-5...5021
          Large Shocks When Starting and Shifting Gears...5021
        H-6...5025
          Large Time Lag When Starting and Shifting Gear...5025
        H-7...5029
          Torque Converter Oil Temperature is High...5029
        H-8...5030
          Steering Does Not Turn...5030
        H-9...5031
          Steering Does Not Turn (Joystick Steering, if equipped)...5031
        H-10...5032
          Steering Response is Poor...5032
        H-11...5033
          Steering, Turning Response is Poor (Joystick Steering, if Equipped)...5033
        H-12...5034
          Steering is Heavy...5034
        H-13...5035
          When Machine Turns, It Shakes or Jerks...5035
        H-14...5036
          When Machine Turns, It Shakes or Jerks (Joystick Steering, if Equipped)...5036
        H-15...5037
          Wheel Brake Does Not Work or Does Not Work Well...5037
        H-16...5038
          Wheel Brake is Not Released or It Drags...5038
        H-17...5039
          Parking Brake Does Not Work or Does Not Work Well...5039
        H-18...5040
          Parking Brake is Not Released or It Drags...5040
        H-19...5041
          Lift Arm Does Not Rise...5041
        H-20...5042
          Lift Arm Speed is Low or Rising Force is Insufficient...5042
        H-21...5043
          When Rising, Lift Arm Starts to Move Slowly at a Specific Height...5043
        H-22...5043
          Lift Arm Cylinder Cannot Hold Down Bucket (Bucket Floats)...5043
        H-23...5043
          Hydraulic Drifts of the Lift Arm Are Large...5043
        H-24...5044
          Lift Arm Wobbles During Operation...5044
        H-25...5045
          Bucket Does Not Tilt Back...5045
        H-26...5046
          Bucket Speed is Low or Tilting-Back Force Is Insufficient...5046
        H-27...5047
          Bucket Starts to Operate Slowly in the Midst of Tilting Back...5047
        H-28...5047
          Bucket Cylinder Cannot Hold Down the Bucket...5047
        H-29...5047
          Hydraulic Drifts of the Bucket Are Large...5047
        H-30...5048
          Bucket Wobbles During Travel with Load...5048
        H-31...5049
          Lift Arm and Bucket Control Levers Do Not Move Smoothly and Are Heavy...5049
        H-32...5050
          During Operation of Machine, Engine Speed Drops Remarkably or Engine Stalls...5050
        H-33...5050
          Large Shocks When Work Equipment Starts and Stops...5050
        H-34...5050
          When Work Equipment Circuit is Relieved Singly, Other Work Equipment Moves...5050
        Troubleshooting Hydraulic and Mechanical Systems...5007
          Using Troubleshooting Chart...5007
        Failure Codes and Causes Table...5009
    50 DISASSEMBLY AND ASSEMBLY...5052
      HOW TO READ THIS MANUAL...5056
        Removal and Installation of Assemblies...5056
        Disassembly and Assembly of Assemblies...5058
      COATING MATERIALS LIST...5060
      SPECIAL TOOLS LIST...5063
      SKETCHES OF SPECIAL TOOLS...5066
      CONNECTOR REPAIR PROCEDURES...5072
        Stripping Insulation...5072
        Wire Inspection...5072
        Contact Terminal Removal (HD30 Type)...5073
        Crimping Contact Terminal (HD30 Type)...5074
        Insertion Of Contact Terminal (HD30 Type)...5075
        Contact Terminal Removal (DT Type)...5076
        Crimping Contact Terminal (DT Type)...5077
        Insertion Of Contact Terminal (DT Type)...5078
      ENGINE AND COOLING SYSTEM...5079
        Alternator...5079
        Crankshaft...5079
        Camshaft...5079
        Engine Front Seal...5079
        Engine Oil Cooler...5079
        Engine Rear Seal...5079
        Starting Motor...5079
        Thermostat...5079
        Turbocharger...5079
        Water Pump...5079
        Cylinder Head...5080
          Removal...5080
          Installation...5086
        Engine Hood...5093
          Removal...5093
          Installation...5095
        Radiator...5096
          Removal...5096
          Installation...5097
        Air Aftercooler...5098
          Removal...5098
          Installation...5099
        Hydraulic Oil Cooler...5100
          Removal...5100
          Installation...5101
        Engine...5102
          Removal...5102
          Installation...5107
        Cooling Fan and Fan Motor...5109
          Removal...5109
          Installation...5112
      FUEL SUPPLY SYSTEM...5113
        Fuel Supply Pump...5113
          Removal...5113
          Installation...5114
        Fuel Injector...5115
          Removal...5115
          Installation...5118
        Fuel Tank...5123
          Removal...5123
          Installation...5125
      POWER TRAIN...5126
        Torque Converter and Transmission Assembly...5126
          Removal...5126
          Installation...5133
        Torque Converter (Standard Specification)...5134
          Disassembly...5134
          Assembly...5137
        Torque Converter (Lockup Specification)...5140
          Disassembly...5140
          Assembly...5143
        Transmission...5148
          Disassembly...5148
          Assembly...5158
        Clutch Pack...5169
          Forward and Reverse Clutch Pack: Disassembly...5169
          1st and 4th Clutch Pack: Disassembly...5173
          2nd and 3rd Gear Clutch Pack: Disassembly...5176
          Forward and Reverse Clutch Pack: Assembly...5182
          1st and 4th Clutch Pack: Assembly...5186
          2nd and 3rd Clutch Pack: Assembly...5190
        Parking Brake...5195
          Disassembly...5195
          Assembly...5200
        Front Axle...5207
          Removal...5207
          Installation...5208
        Rear Axle...5209
          Removal...5209
          Installation...5212
        Axle Housing...5214
          Disassembly...5214
          Assembly...5219
        Differential Assembly...5226
          Disassembly...5226
          Assembly...5235
      STEERING SYSTEM...5251
        Steering Valve Assembly...5251
          Removal...5251
          Installation...5253
      BRAKING SYSTEM...5254
        Parking Brake Discs and Plates...5254
          Removal...5254
          Installation...5256
      UNDERCARRAGE AND FRAME...5257
        Center Hinge Pin...5257
          Removal...5257
          Installation...5262
        Counterweight...5267
          Removal...5267
          Installation...5269
      HYDRAULIC SYSTEM...5270
        Work Equipment Control Valve...5270
          Removal...5270
          Installation...5272
        Power Train Pump and Work Equipment Pump Assembly...5273
          Removal...5273
          Installation...5273
        Steering Pump And Cooling Fan Pump Assembly...5274
          Removal...5274
          Installation...5275
        Hydraulic Tank...5276
          Removal...5276
          Installation...5279
      WORK EQUIPMENT...5280
        Work Equipment Assembly...5280
          Removal...5280
          Installation...5283
        Hydraulic Cylinder...5285
          Disassembly...5285
          Assembly...5289
      CAB AND ATTACHMENTS...5294
        Cab and Floor Frame...5294
          Removal...5294
          Installation...5297
        Cab Glass (Stuck Glass)...5298
          Removal...5298
          Installation...5299
        Operator Seat Assembly (Standard Specification) (ISRING HAUSEN)...5307
          Disassembly...5307
          Assembly...5314
        Operator Seat Assembly (GRAMMER)...5319
          Upper Seat...5319
          Suspension...5327
      AIR CONDITIONER UNIT ASSEMBLY...5355
        Removal...5355
        Installation...5359
      ELECTRICAL SYSTEM...5360
        Engine Controller Assembly...5360
          Removal...5360
          Installation...5360
    90 DIAGRAMS AND SCHEMATICS...5362
      AUTOMATIC GREASING...5364
        Auto-Grease Circuit Diagram...5364
      HYDRAULIC SYSTEM...5365
        Power Train Hydraulic Circuit Diagram...5365
          Without Lockup Clutch...5365
          With Lockup Clutch...5365
        Hydraulic Circuit Diagram...5366
      ELECTRICAL SYSTEM...5367
        Machine Monitor System Circuit Diagram...5367
        Transmission Controller System Circuit Diagram...5368
        Work Equipment Controller System Diagram...5369
        Work Equipment Controller System Electrical Circuit Diagram...5370
        Electrical Circuit Diagram (1/14)...5371
        Electrical Circuit Diagram (2/14)...5372
        Electrical Circuit Diagram (3/14)...5373
        Electrical Circuit Diagram (4/14)...5374
        Electrical Circuit Diagram (5/14)...5375
        Electrical Circuit Diagram (6/14)...5376
        Electrical Circuit Diagram (7/14)...5377
        Electrical Circuit Diagram (8/14)...5378
        Electrical Circuit Diagram (9/14)...5379
        Electrical Circuit Diagram (10/14)...5380
        Electrical Circuit Diagram (11/14)...5381
        Electrical Circuit Diagram (12/14)...5382
        Electrical Circuit Diagram (13/14)...5383
        Electrical Circuit Diagram (14/14)...5384
        Connector List and Stereogram...5385
          Chassis...5385
          Engine and Transmission...5386
          Operator's Compartment...5387
CEBM025604 - Wheel Loader WA380-7 Shop Manual...5388
  CEBM025604 WA380-7 S/N A64001 and UP...5388
    CONTENTS...5389
    00 FOREWORD...5411
      SAFETY...5411
        Safety Notice...5411
          Important Safety Notice...5411
          General Precautions...5411
          Preparations For Work...5412
          Precautions During Work...5412
      GENERAL...5415
      HOW TO READ THE SHOP MANUAL...5416
        Volumes...5416
        Distribution And Updating...5416
        Filing Method...5416
        Revised Edition Mark...5416
        Revisions...5416
        Symbols...5416
        Unit...5416
      HOISTING INSTRUCTIONS...5417
        Hoisting...5417
        Making Signs...5417
        Precautions...5417
          Precautions for Sling Work...5417
          Precautions for Using Mobile Crane...5418
          Precautions for Using Overhead Hoist Crane...5418
        Selecting Wire Ropes...5420
      HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS...5421
        Points to Remember When Handling Electric Equipment...5421
        Points to Remember When Handling Hydraulic Equipment...5433
      PUSH PULL COUPLER...5435
        Type 1...5435
          Disconnection...5435
          Connection...5435
        Type 2...5436
          Disconnection...5436
          Connection...5436
        Type 3...5437
          Disconnection...5437
          Connection...5437
      EXPLANATION OF MAINTENANCE STANDARD TERMS...5438
      HANDLING OF FUEL SYSTEM DEVICES...5439
      HANDLING OF INTAKE SYSTEM PARTS...5440
      STANDARD TIGHTENING TORQUE...5441
        Bolts and Nuts...5441
        Tightening Torque of Hose Nuts...5442
        Tightening Torque of Split Flange Bolts...5442
        Tightening Torque for Flared Nuts...5442
        Tightening Torques for Split Flanged Bolts...5443
        Tightening Torques for O-ring Boss Piping Joints...5443
        Table Of Tightening Torques for O-ring Boss Plugs...5443
        Tightening Torque for Hoses (Taper Seal Type and Face Seal Type)...5444
        Tightening Torque for Face Seal Joints...5444
        For 102, 107, and 114 Engine Series (Bolts and Nuts)...5444
        For 102, 107, and 114 Engine Series (Eye Joints)...5445
        For 102, 107, and 114 Engine Series (Taper Screws)...5445
      ELECTRIC WIRE CODE...5446
        Classification By Thickness...5446
        Classification By Color And Code...5446
        How To Read Electric Wire Code...5447
      PRECAUTIONS FOR OPERATIONS...5451
        Precautions When Carrying Out Removal Work...5451
        Precautions When Carrying Out Installation Work...5452
        Precautions When Completing the Operation...5453
      CONVERSION TABLES...5454
        Method Of Using The Conversion Table...5454
      COATING MATERIALS...5460
      LIST OF ABBREVIATIONS...5462
        List of Abbreviations Used in the Shop Manual...5462
        List of Abbreviations Used in the Circuit Diagrams...5466
    01 GENERAL...5468
      SPECIFICATIONS...5469
        Dimension Drawing...5469
        Specification Tables...5471
      WEIGHT TABLE...5477
      FUEL, COOLANT, AND LUBRICANTS...5479
    10 STRUCTURE AND FUNCTION...5482
      ENGINE AND COOLING SYSTEM...5491
        Engine Related Parts...5491
        KVGT...5493
          Operation...5494
        EGR System Piping Drawing...5499
          Function...5500
        EGR System Circuit Diagram...5501
        EGR Valve...5502
          Structure...5502
          Operation...5503
        EGR Cooler...5504
          Operation...5504
        KCCV Layout Drawing...5505
          Operation...5506
        KCCV Ventilator...5507
          Function...5507
          Operation...5508
          CDR Valve...5508
        KDPF...5509
          Function...5511
          Types of Regeneration...5511
        Cooling System...5513
          Specification...5514
        Cooling Fan Pump...5515
          Specification...5517
          Function...5518
          Operation...5518
        Servo Valve...5519
          Function...5520
          Operation...5520
        Cooling Fan Motor System...5521
          Specifications...5521
        Hydraulic Motor...5523
        Suction Valve...5524
          Function...5524
          Operation...5524
        Reversible Valve...5525
        Safety Valve...5526
      POWER TRAIN SYSTEM...5527
        Power Train System...5527
        System Diagram...5529
        Drive Shaft System...5531
          Function...5531
        Power Train Piping System...5532
        Transmission Control...5533
          Function...5534
        Torque Converter...5535
          Specification...5535
        Power Transmitting Route...5536
          Oil Flow...5537
        Transmission...5539
        Forward and Reverse Clutches...5544
          1st and 4th Clutches...5545
          2nd and 3rd Clutches...5546
          Structure...5546
          Operation of Clutch Pack...5548
        Power Transmitting Route...5549
          Forward 1st...5549
          Forward 2nd...5551
          Forward 3rd...5553
          Forward 4th...5555
          Reverse 1st...5557
        Transmission Control Valve...5559
          Function...5560
        Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV...5561
          ECMV For Gear Speed Clutch...5562
        Lockup Clutch ECMV...5565
          ECMV for Lockup Clutch...5566
          Operation...5566
        Main and Torque Converter Relief Valve System...5568
          Function...5569
          Operation...5569
      DRIVE AXLE SYSTEM...5571
        Front Axle Assembly...5571
        Rear Axle Assembly...5572
        Front Differential...5573
        Rear Differential...5574
          Operation...5575
        Limited Slip Differential...5576
          Operation...5576
        Final Drive...5579
      STEERING SYSTEM...5581
        Layout of Steering Devices...5581
        Steering Column...5582
        Steering Pump...5583
          Pump Body...5585
          Specification...5588
          Operation...5588
          Servo Valve...5590
          LS Valve...5593
          PC Valve...5593
        Steering Valve...5597
          Operation of Flow Amplifier...5599
          Operation of Flow Control Spool...5600
          Operation of Steering Valve...5602
          Steering Relief Valve...5605
          Overload Relief Valve...5606
          Relief Valve...5607
        Orbitrol Valve...5608
        Stop Valve...5612
        Emergency Steering Motor...5613
          Function...5613
          Specifications...5613
        Emergency Steering Pump...5614
          Specification...5614
      BRAKE SYSTEM...5615
        Layout of brake parts...5615
        Charge Valve...5616
        Brake Valve...5622
          Function...5622
        Accumulator (for Brakes)...5627
          Function...5627
          Specifications...5627
        Brakes...5628
          Front Brake...5628
          Rear Brake...5629
          Operation...5630
        Parking Brake System...5631
          Brake Control...5631
          Parking Brake Unit...5632
          Parking Brake Solenoid Valve...5633
          Emergency Parking Brake Release Valve...5634
      UNDERCARRIAGE AND FRAME...5635
        Axle Mounting and Center Hinge Pin...5635
        Tires...5636
          Radial Ply Tire...5636
          Bias Tire...5637
      HYDRAULIC SYSTEM...5639
        Hydraulic Component Layout...5639
        Work Equipment Control Lever System...5641
          3-Lever Type...5641
          Multi-Function Mono-Lever Type...5642
        Hydraulic Tank...5643
          Specifications...5644
          Breather...5644
        Double Type Gear Pump...5645
          Specification...5645
          Function...5645
        Work Equipment Pump...5647
        Pump Body...5649
          Function...5651
          Structure...5651
          Specification...5652
          Operation...5652
        Servo Valve...5655
          LS Valve...5658
          PC Valve...5659
        Control Valve...5663
          Structure...5672
        CLSS...5673
          Outline of CLSS...5673
        Features...5673
          Structure...5673
          Basic Principle...5674
          Pressure Compensation Control...5675
        Function and Operation of Each Valve...5677
          Hydraulic Circuit Diagram of Valves...5677
          Unload Valve...5678
          Work Equipment Valve (Supply of LS Pressure)...5681
          LS Bypass Plug...5683
          Pressure Compensation Valve...5685
          Boom Regeneration Circuit...5689
          Variable Back Pressure Valve...5691
          ECSS Control Valve...5692
          Accumulator Charge Valve...5693
          Stabilizer Valve...5697
          Work Equipment Lock Solenoid Valve...5702
        Accumulator (for PPC Circuit)...5703
          Function...5703
          Specifications...5703
        Accumulator (for ECSS)...5704
      WORK EQUIPMENT...5705
        Work Equipment Linkage...5705
        Bucket...5706
        Bucket Positioner and Boom Positioner...5707
      CAB AND ITS ATTACHMENTS...5708
        ROPS Cab...5708
      ELECTRICAL SYSTEM...5709
        Engine Control System...5709
          Function...5710
          Operation...5710
        Preheating System...5711
          Automatic Preheating System...5711
          Manual Preheating System...5712
        Engine Power Mode Selector Circuit...5713
          Function...5713
          Operation...5713
        Engine Output Limit Function...5714
        Automatic Warm-up Function...5714
        Parking Brake Control System...5715
          Operation...5715
        System Operating Lamp Function...5719
          Function...5719
        Battery Disconnect Switch Function...5721
          Function...5721
        Transmission Controller System...5723
          Transmission Controller System Diagram...5723
          Transmission Gear Shift Control Function...5725
          Transmission Protection Function...5743
          Engine Control Function...5745
          ECSS Function...5755
          Directional Switch Control Function...5756
          Auto Idle Stop Function...5757
          Real-time Monitoring Function Of Transmission Controller...5758
          Transmission Controller Self-Diagnosis Function...5758
        Work Equipment Control System...5759
          Work Equipment Control System Diagram...5759
          Work Equipment Control Function...5761
          Work Equipment Neutral Lock Function...5762
          Neutral Position and Work Equipment Speed...5764
          Bucket Priority Control...5765
          Boom Stop Modulation...5765
          Adjustment of Lever Detent Position and Work Equipment Starting Current...5766
          Swash Plate Control Function of Work Equipment Pump and Steering Pump...5766
          Overheat Prevention Function of Work Equipment Controller...5770
          Remote Positioner Function...5770
          Semi Auto-Digging Function...5776
          Electric Emergency Steering Function...5779
          Real-Time Monitoring Function of Work Equipment Controller...5780
          Self-Diagnosis Function of Work Equipment Controller...5780
        Machine Monitor System...5781
          Function...5782
          Details of Monitor Controller Network Signals...5782
          Machine Monitor...5786
          Switch Panel...5805
          Rear View Monitor System...5807
          Rear View Monitor...5807
          Rear View Camera...5809
        KOMTRAX System...5810
          KOMTRAX Terminal...5811
          System Component Parts...5813
          Work Equipment Controller...5819
          Transmission Controller...5823
          Machine Controller...5827
          Work Equipment Electric Lever...5833
          Throttle Position Sensor...5835
          Combination Switch...5837
          Kickdown Switch...5839
          Hold Switch...5839
          CAN Terminating Resistor...5840
          Specifications...5840
          Engine Oil Pressure Switch...5841
          Specifications...5841
          Front Brake Oil Pressure Switch...5841
          Specification...5841
          Rear Brake Oil Pressure Switch...5842
          Specification...5842
          Stop Lamp Oil Pressure Switch...5842
          Specification...5842
          Parking Brake Oil Pressure Switch...5843
          Specification...5843
      SENSORS...5845
        Ambient Pressure Sensor...5845
          Function...5845
        Coolant Temperature Sensor...5845
          Function...5846
        Ne (Crankshaft) Speed Sensor...5846
        Bkup (Camshaft) Speed Sensor...5846
          Function...5846
        Common Rail Pressure Sensor...5847
          Function...5847
        Exhaust Manifold Pressure Sensor...5847
          Function...5847
        EGR Orifice Temperature Sensor...5848
        EGR Valve Lift Sensor...5848
          Function...5848
        KVGT Speed Sensor...5849
          Function...5849
        KVGT Position Sensor...5850
          Function...5850
          Output characteristics...5850
        Mass Air Flow and Temperature Sensor...5851
          Function...5851
        KDPF Differential Pressure and Outlet Pressure Sensor...5851
          Function...5851
        KDOC Inlet Temperature Sensor...5852
          Function...5852
        KDOC Outlet Temperature Sensor...5852
          Function...5852
        KDPF Outlet Temperature Sensor...5853
          Function...5853
        Crankcase Pressure Sensor...5853
          Function...5853
        Engine Oil Level Sensor...5854
          Function...5854
        Transmission Input Speed Sensor...5854
          Function...5854
        Transmission Output Shaft Speed Sensor...5855
          Function...5855
        Cooling Fan Speed Sensor...5855
          Function...5855
        Torque Converter Oil Temperature Sensor...5856
          Function...5856
        Transmission Oil Temperature Sensor...5856
          Function...5856
        Hydraulic Oil Temperature Sensor...5857
          Function...5857
        Brake Oil Temperature Sensor...5857
          Function...5857
        Transmission Inlet Pressure Sensor...5858
          Function...5858
          Output characteristics...5858
        Transmission Outlet Pressure Sensor...5859
          Function...5859
          Output characteristics...5859
        Oil Pressure Sensor of Work Equipment Pump...5860
          Function...5860
          Output characteristics...5860
        Steering Pump Oil Pressure Sensor...5860
          Function...5860
          Output characteristics...5861
        Emergency Steering Pump Pressure Sensor...5861
          Function...5861
          Output characteristics...5861
        Boom Cylinder Bottom Oil Pressure Sensor...5862
          Function...5862
          Output characteristics...5862
        Transmission Cut-off Oil Pressure Sensor...5863
          Function...5863
          Output characteristics...5863
        Coolant Level Sensor...5864
          Function...5864
        Fuel Level Sensor...5865
          Function...5865
        Air Cleaner Clogging Sensor...5866
          Function...5866
        Water-in-Fuel Sensor...5866
          Function...5866
        Boom Potentiometer...5867
          Function...5867
          Output characteristics...5867
        Bucket Potentiometer Sensor...5868
          Function...5868
          Output characteristics...5868
      QUICK COUPLER...5869
        Quick Coupler Switch...5869
        Quick Coupler Solenoid Valve...5870
        Outline...5870
    20 STANDARD VALUE TABLES...5872
      STANDARD VALUE TABLES...5873
        Service Value For Engine...5873
        Service Values For Chassis...5875
          Directional Levers...5875
          Gear Speed Switch...5875
          Work Equipment Levers...5876
          Multi-Function Mono-Lever...5877
          Steering Wheel...5878
          Frame...5878
          Accelerator Pedal...5879
          Brake Pedal...5879
          Tires...5879
          Engine Speed...5880
          Transmission and Torque Converter...5880
          Steering...5881
          Accumulator...5881
          Power Train...5881
          Wheel Brake...5883
          Parking Brake...5884
          PPC...5884
          Work Equipment...5885
          Hydraulic Fan...5886
        Machine Posture...5887
    30 TESTING AND ADJUSTING...5890
      TOOLS...5895
        Tools for Testing, Adjusting, and Troubleshooting...5895
        Sketch of Tools for Testing and Adjusting...5901
      ENGINE AND COOLING SYSTEM...5903
        Measuring Engine Speed...5903
          Measurement Conditions...5903
          Testing...5903
        Measuring Boost Pressure...5905
          Measuring With Machine Monitor...5905
          Measuring by Use of Testing Tools...5905
        Testing Exhaust Gas Temperatures...5907
          Testing...5907
        Testing Exhaust Gas Color...5911
          Testing...5911
        Testing and Adjusting Valve Clearance...5915
          Testing...5915
          Adjusting...5917
        Measuring Compression Pressure...5919
          Testing...5919
        Measuring Blow-By Pressure...5925
        Measuring Engine Oil Pressure...5927
        Measuring EGR Valve and KVGT Oil Pressure...5929
          Testing...5929
        Testing Fuel Pressure...5931
          Testing...5932
          Testing Low-Pressure Circuit (Pressure Difference)...5933
          Testing Return Circuit...5934
          Testing Negative-Pressure Circuit...5935
        Measuring Fuel Delivery, Return and Leakage...5937
          Testing...5938
          Testing Supply Pump Return Rate...5939
          Testing Leakage from Pressure Limiter...5941
          Testing Fuel Return Rate from Injector...5942
          Bleeding Air from Fuel System...5943
        Checking Fuel Circuit for Leakage...5945
        Handling Cylinder Cut-Out Mode Operation...5946
        Handling No-Injection Cranking Operation...5946
          Check of KDPF and Muffler Stack for Looseness and Damage...5946
          Check of Installed Condition of Cylinder Head and Manifolds...5946
          Checking Engine Piping for Damage and Looseness...5946
          Testing and Adjusting Air Conditioner Compressor Belt Tension...5947
          Replacing Alternator Belt...5948
      POWER TRAIN SYSTEM...5949
        Adjusting Transmission Output Speed Sensor...5949
          Adjustment...5949
        Adjusting Transmission Input Speed Sensor...5950
          Adjustment...5950
        Flushing Procedure for Torque Converter and Transmission Hydraulic Circuit...5951
          Flushing Procedures...5951
        Retrieval of Disabled Machine Due to Transmission Valve Failure...5953
          How to Move...5953
          Checking Oil Leakage from Axle Final Drive...5954
          Checking Drive Shaft for Looseness, Play, and Damage...5955
        Testing and Adjusting Power Train Oil Pressure...5957
          Testing...5961
          Adjustment...5974
      STEERING SYSTEM...5975
        Checking Directional Lever...5975
          Testing...5975
        Testing Steering Wheel...5977
          Testing...5977
        Testing Work Equipment Control Lever...5979
          Testing...5979
        Testing and Adjusting Steering Circuit Pressure...5981
          Testing...5981
          Adjustment...5983
        Bleeding Air from Steering Cylinder Circuit...5984
          Bleeding Air...5984
        Testing and Adjusting Steering Stopper Valve...5985
          Testing...5985
          Adjustment...5985
      BRAKE SYSTEM...5987
        Testing Brake Pedal...5987
          Testing...5987
        Testing and Adjusting Brake Pedal Linkage...5988
          Testing...5988
          Adjustment...5988
        Testing Braking Performance...5989
          Testing...5989
        Testing and Adjusting Accumulator Charge Pressure...5991
          Testing...5991
          Adjusting...5992
        Testing Wheel Brake Oil Pressure...5993
          Testing...5993
        Measuring Lowering of Wheel Brake Pressure...5995
          Testing...5995
          Brake Test Kit...5997
        Measuring Wear of Wheel Brake Disc...5998
          Testing...5998
        Bleeding Air From Wheel Brake Circuit...5999
          Bleeding Air...5999
        Releasing Remaining Pressure in Brake Accumulator Circuit...6000
          Releasing Remaining Pressure...6000
        Testing Parking Brake Performance...6000
          Testing...6000
        Testing Parking Brake Oil Pressure...6001
          Testing...6001
        Testing Wear of Parking Brake Disc...6003
          Testing...6003
        Method of Releasing Parking Brake Manually...6005
          How to Release...6005
      HYDRAULIC SYSTEM...6007
        Checking Fan Speed...6007
          Testing...6007
        Measuring Fan Pump Circuit Oil Pressure...6009
          Testing...6009
        Bleeding Air from Hydraulic Fan Circuit...6011
          Bleeding Air...6011
        Testing and Adjusting Work Equipment PPC Oil Pressure...6013
          Testing...6013
          Adjustment...6015
        Testing and Adjusting Work Equipment Oil Pressure...6017
          Preparation...6017
          Testing...6018
        Bleeding Air from Work Equipment Circuit...6021
          Bleeding Air from Work Equipment Pump (Piston Pump)...6021
          Bleeding Air from Cylinder...6021
        Releasing Remaining Pressure from Work Equipment Circuit...6023
          Releasing Remaining Pressure Between Each Hydraulic Cylinder and Control Valve...6023
          Releasing Remaining Pressure In ECSS Circuit...6023
        Checking of ECSS Accumulator Nitrogen Gas Pressure and Procedure for Charging Accumulator with Nitrogen Gas...6025
          Testing Nitrogen Gas Pressure in Accumulator...6025
        Procedure for Charging Accumulator with Nitrogen Gas...6028
      WORK EQUIPMENT...6033
        Testing and Adjusting Bucket Position Detection Lever...6033
          Testing...6033
          Adjustment...6033
        Testing and Adjusting Boom Position Detection Lever...6034
          Testing...6034
          Adjustment...6034
      ELECTRICAL SYSTEM...6035
        Adjusting Replaced, Reassembled or Added Sensor, Controller, Etc. with Machine Monitor...6035
        Special Functions of Machine Monitor...6037
          Ordinary Functions and Special Functions of Machine Monitor...6038
          Operator Mode (outline)...6040
          Service Mode...6053
        Angle Adjustment of Rear View Camera...6147
          Adjustment...6148
          Handling Voltage Circuit of Engine Controller...6148
        Handling Battery Disconnect Switch...6149
        Testing Diodes...6150
          Testing...6150
      PM-CLINIC INSPECTION TABLE...6151
        Check Sheet...6152
    40 TROUBLESHOOTING...6158
      POINTS TO REMEMBER WHEN TROUBLESHOOTING...6171
      PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...6174
        Precautions when Handling Electrical Equipment...6174
        Handling Electronic Control Unit...6179
        Points to Remember when Troubleshooting Electrical Circuits...6180
      ELECTRIC WIRE CODE...6181
        Classification by Thickness...6181
        Classification by Color and Code...6181
        How to Read Electric Wire Code...6182
          Type, Symbol, and Material...6182
          Dimensions...6183
      HANDLING HYDRAULIC EQUIPMENT...6184
      CHECKS BEFORE TROUBLESHOOTING...6186
        Testing Procedure Before Troubleshooting...6188
          Walk-Around Check...6188
        Categories and Method of Using Troubleshooting Charts...6196
        Information Mentioned in Troubleshooting Table...6199
        Connector List...6201
        Layout of Connectors (1/7)...6215
        Layout of Connectors (2/7)...6216
        Layout of Connectors (3/7)...6217
        Layout of Connectors (4/7)...6218
        Layout of Connectors (5/7)...6219
        Layout of Connectors (6/7)...6220
        Layout of Connectors (7/7)...6221
        Diagnostic Procedure for Wiring Harness Open Circuit of Pressure Sensor System...6223
        Fuse Location Table...6226
        Precautions for Cleaning and Replacing KDPF (KCSF, KDOC)...6229
        Dummy Temperature Sensor (for KDOC and KDPF Temperature Sensors)...6233
        Short-Circuit Connector (for CA1883 and CA3135)...6234
        Precautions on Troubleshooting of Machine Monitor...6235
        Processing Procedure of Harness Checker for Troubleshooting of Machine Monitor LCD Unit...6237
      TROUBLESHOOTING BY FAILURE CODE...6243
        Failure Code Table...6243
      FAILURE CODES...6255
        [1500L0] Double Engagement of T/M Clutches...6255
        [15SAL1] Release Trouble of ECMV (Forward)...6257
        [15SALH] Malfunction of ECMV (Forward)...6259
        [15SBL1] Release Trouble of ECMV (Release)...6261
        [15BLH] Malfunction of ECMV (Reverse)...6263
        [15SEL1] Release Trouble of ECMV (1st)...6265
        [15SELH] Malfunction of ECMV (1st)...6267
        [15SFL1] Release Trouble of ECMV (2nd)...6269
        [15SFLH] Malfunction of ECMV (2nd)...6271
        [15SGL1] Release Trouble of ECMV (3rd)...6273
        [15SGLH] Malfunction of ECMV (3rd)...6275
        [15SHL1] Release Trouble of ECMV (4th)...6277
        [15SHLH] Malfunction of ECMV (4th)...6279
        [2F00MA] Failure of Parking Brake Circuit...6281
        [2G42ZG] Accumulator Oil Pressure Low (Front)...6285
        [2G43ZG] Accumulator Oil Pressure Low (Rear)...6287
        [879AKA] A/C Inner Sensor Open Circuit...6289
        [879AKB] A/C Inner Sensor Short Circuit...6291
        [879BKA] A/C Outer Sensor Open Circuit...6293
        [879BKB] A/C Outer Sensor Short Circuit...6295
        [879CKA] Ventilating Sensor Open Circuit...6297
        [879CKB] Ventilating Sensor Short Circuit...6299
        [879DKZ] Sunlight Sensor Open or Short Circuit...6301
        [879EMC] Ventilation Damper Abnormality...6303
        [879FMC] Air Mix Damper Abnormality...6306
        [989A00] Engine Overrun Protection Activated...6309
        [989L00] Engine Controller Lock Caution 1...6309
        [989M00] Engine Controller Lock Caution 2...6310
        [989N00] Engine Controller Lock Caution 3...6310
        [A1U0N3] HC Desorb Request 1...6311
        [A1U0N4] HC Desorb Request 2...6313
        [AA10NX] Air Cleaner Clogging...6315
        [B@BAZG] Eng Oil Press Low...6317
        [B@BAZK] Eng Oil Level Low...6319
        [B@BCNS] Eng Water Overheat...6321
        [B@BCZK] Eng Water Level Low...6323
        [B@CENS] T/C Oil Temp. Overheat...6325
        [B@HANS] HYD Oil Temp. Overheat...6326
        [CA115] Eng Ne and Bkup Speed Sens Error...6326
        [CA122] Chg Air Press Sensor High Error...6327
        [CA123] Chg Air Press Sensor Low Error...6329
        [CA131] Throttle Sensor High Error...6331
        [CA132] Throttle Sensor Low Error...6333
        [CA144] Coolant Temp Sens High Error...6335
        [CA145] Coolant Temp Sens Low Error...6337
        [CA153] Chg Air Temp Sensor High Error...6339
        [CA154] Chg Air Temp Sensor High Error...6341
        [CA187] Sensor 2 Supply Volt Low Error...6343
        [CA221] Ambient Press Sensor High Error...6345
        [CA222] Ambient Press Sensor Low Error...6347
        [CA227] Sensor 2 Supply Volt High Error...6350
        [CA234] Eng Overspeed...6350
        [CA238] Ne Speed Sensor Supply Volt Error...6351
        [CA239] Ne Speed Sens Supply Volt High Error...6353
        [CA271] IMV/PCV1 Short Error...6355
        [CA272] IMV/PCV1 Open Error...6357
        [CA295] Ambient Press Sens In Range Error...6359
        [CA322] Inj #1 (L#1) Open/Short Error...6360
        [CA323] Inj #5 (L#5) Open/Short Error...6362
        [CA324] Inj #3 (L#3) Open/Short Error...6364
        [CA325] Inj #6 (L#6) Open/Short Error...6366
        [CA331] Inj #2 (L#2) Open/Short Error...6368
        [CA332] Inj #4 (L#4) Open/Short Error...6370
        [CA343] ECM Critical Internal Failure...6372
        [CA351] Injectors Drive Circuit Error...6372
        [CA352] Sensor 1 Supply Volt Low Error...6373
        [CA356] Mass Air Flow Sensor High Error...6375
        [CA357] Mass Air Flow Sensor Low Error...6377
        [CA386] Sensor 1 Supply Volt High Error...6380
        [CA428] Water in Fuel Sensor High Error...6381
        [CA429] Water in Fuel Sensor Low Error...6383
        [CA431] Idle Validation Switch Error...6385
        [CA432] Idle Validation Process Error...6389
        [CA435] Eng Oil Press Sw Error...6393
        [CA441] Battery Voltage Low Error...6395
        [CA442] Battery Voltage High Error...6397
        [CA449] Rail Press Very High Error...6398
        [CA451] Rail Press Sensor High Error...6399
        [CA452] Rail Press Sensor Low Error...6401
        [CA488] Chg Air Temp High Torque Derate...6403
        [CA515] Rail Press Sens Sup Volt High Error...6405
        [CA516] Rail Press Sens Sup Volt Low Error...6407
        [CA553] Rail Press High Error...6409
        [CA555] Crankcase Press High Error 1...6409
        [CA556] Crankcase Press High Error 2...6410
        [CA559] Rail Press Low Error...6411
        [CA595] Turbo Speed High Error 2...6412
        [CA687] Turbo Speed Low Error...6413
        [CA689] Eng Ne Speed Sensor Error...6415
        [CA691] Intake Air Temp Sens High Error...6419
        [CA692] Intake Air Temp Sens Low Error...6421
        [CA697] ECM Int Temp Sensor High Error...6423
        [CA698] ECM Int Temp Sensor Low Error...6424
        [CA731] Eng Bkup Speed Sens Phase Error...6425
        [CA778] Eng Bkup Speed Sensor Error...6427
        [CA1117] Persistent Data Lost Error...6431
        [CA1664] KDOC Malfunction...6432
        [CA1691] Regeneration Ineffective...6435
        [CA1695] Sensor 5 Supply Volt High Error...6439
        [CA1696] Sensor 5 Supply Volt Low Error...6441
        [CA1843] Crankcase Press Sens High Error...6443
        [CA1844] Crankcase Press Sens Low Error...6445
        [CA1879] KDPF Delta P Sensor High Error...6447
        [CA1881] KDPF Delta P Sensor Low Error...6449
        [CA1883] KDPF Delta P Sens In Range Error...6451
        [CA1921] KDPF Soot Load High Error 1...6457
        [CA1922] KDPF Soot Load High Error 2...6459
        [CA1942] Crankcase Press Sens In Range Error...6463
        [CA1993] KDPF Delta Pressure Low Error...6464
        [CA2185] Throt Sensor Sup Volt High Error...6467
        [CA2186] Throt Sensor Sup Volt Low Error...6469
        [CA2249] Rail Press Very Low Error...6470
        [CA2271] EGR Valve Pos Sens High Error...6471
        [CA2272] EGR Valve Pos Sens Low Error...6475
        [CA2288] Turbo Speed High Error 1...6479
        [CA2311] IMV Solenoid Error...6479
        [CA2349] EGR Valve Solenoid Open Error...6481
        [CA2353] EGR Valve Solenoid Short Error...6483
        [CA2357] EGR Differential Pressure...6485
        [CA2373] Exh Manifold Press. Sens High Error...6487
        [CA2374] Exhaust Manifold Press Sens Low Error...6489
        [CA2375] EGR Orifice Temp Sens High Error...6491
        [CA2376] EGR Orifice Temp Sens Low Error...6493
        [CA2381] KVGT Pos Sens High Error...6495
        [CA2382] KVGT Pos Sens Low Error...6497
        [CA2383] KVGT Solenoid Open Error...6501
        [CA2386] KVGT Solenoid Short Error...6503
        [CA2387] KVGT Servo Error...6505
        [CA2554] Exh Manifold Press Sens In Range Error...6506
        [CA2555] Grid Htr Relay Volt Low Error...6507
        [CA2556] Grid Htr Relay Volt High Error...6509
        [CA2637] KDOC Face Plugging...6511
        [CA2639] Manual Stationary Regeneration Request...6513
        [CA2961] EGR Orifice Temp High Error 1...6515
        [CA2973] Chg Air Press Sensor In Range Error...6516
        [CA3133] KDPF Outlet Press Sens High Error...6517
        [CA3134] KDPF Outlet Press Sens Low Error...6519
        [CA3135] KDPF Outlet Press Sens In Range Error...6521
        [CA3251] KDOC Inlet Temp High Error...6526
        [CA3253] KDOC Temp Error - Non Regeneration...6529
        [CA3254] KDOC Outlet Temp High Error 1...6533
        [CA3255] KDPF Temp Error - Non Regeneration...6537
        [CA3256] KDPF Outlet Temp High Error 1...6541
        [CA3311] KDOC Outlet Temp High Error 2...6545
        [CA3312] KDPF Outlet Temp High Error 2...6549
        [CA3313] KDOC Inlet Temp Sensor Low Error...6553
        [CA3314] KDOC Inlet Temp Sens High Error...6557
        [CA3315] KDOC Inlet Temp Sens In Range Error...6561
        [CA3316] KDOC Outlet Temp Sens Low Error...6567
        [CA3317] KDOC Outlet Temp Sens High Error...6571
        [CA3318] KDOC Inlet Temp Sens In Range Error...6575
        [CA3319] KDPF Outlet Temp Sens High Error...6581
        [CA3321] KDPF Outlet Temp Sens Low Error...6585
        [CA3322] KDPF Outlet Temp Sens In Range Error...6589
        [CA3419] Mass Air Flow Sensor Sup Volt High Error...6595
        [CA3421] Mass Air Flow Sensor Sup Volt Low Error...6597
        [CA3741] Rail Press Valve Trip Error...6599
        [D150KA] Disconnection of Emergency Steering Relay...6601
        [D150KB] Ground Fault of Emergency Steering Relay...6603
        [D150KY] Hot Short of Emergency Steering Relay...6605
        [D160KA] Disconnection of Back-Up Lamp Relay Output...6607
        [D160KB] Ground Fault of Back-Up Lamp Relay Output...6609
        [D160KY] Hot Short of Back-Up Lamp Relay Output...6611
        [D191KA] Disconnection of Neutral Output Relay...6613
        [D191KB] Ground Fault of Neutral Output Relay...6617
        [D191KY] Hot Short of Neutral Output Relay...6621
        [D192KA] Disconnection of ECSS Solenoid...6623
        [D192KB] Ground Fault of ECSS Solenoid...6625
        [D192KY] Hot Short of ECSS Solenoid...6627
        [D19JKZ] Personal Code Relay Abnormality...6629
        [D1E6KA] Disconnection of Parking Brake Relay...6631
        [D1E6KB] Ground Fault of Parking Brake Relay...6633
        [D1E6KY] Hot Short of Parking Brake Relay...6635
        [D5ZHKA] Failure of Key SW C Signal...6637
        [D5ZHKB] Key SW C Signal Short Circuit...6639
        [D5ZHKZ] Failure of Key SW C Signal...6641
        [D5ZHL6] Disconnection of Key SW C...6645
        [D811MC] KOMTRAX Error...6647
        [D862KA] GPS Antenna Open Circuit...6647
        [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)...6649
        [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)...6651
        [D8AQK4] CAN2 Discon (KOMTRAX) 2...6653
        [D8AQKR] CAN2 Discon (KOMTRAX)...6654
        [DAF0KT] Abnormality of Non-volatile Memory (MON)...6655
        [DAF0MB] Monitor ROM Abnormality...6655
        [DAF0MC] Monitor Error...6655
        [DAF3KK] Controller Power Source Low (MON)...6657
        [DAF8KB] Camera Power Supply Short Circuit...6659
        [DAFDKB] Monitor 12 V Power Output Short Circuit...6661
        [DAFGMC] GPS Module Error...6662
        [DAFLKA] Operating Lamp Open Circuit (MON)...6663
        [DAFLKB] Operating Lamp Short Circuit (MON)...6665
        [DAFQKR] CAN2 Discon (Monitor)...6667
        [DAQ0KK] Controller Power Source Low (T/M)...6669
        [DAQ0KT] Abnormality of Non-volatile Memory (T/M)...6673
        [DAQ0MC] T/M Con Error...6674
        [DAQ1KA] Disconnection of Key SWACC (T/M)...6675
        [DAQ2KK] Solenoid Power Source Low (T/M)...6677
        [DAQ4KB] Ground Fault of Sol. Self-Holding Relay (TM)...6681
        [DAQ9KQ] Inconsistency of Model Selection (T/M)...6683
        [DAQLKA] Operating Lamp Open Circuit (T/M)...6685
        [DAQLKB] Operating Lamp Short Circuit (T/M)...6687
        [DAQQKR] CAN2 Discon (Transmission Con)...6689
        [DAQRKR] CAN1 Discon (Transmission Con)...6690
        [DAQRMA] Inconsistency of Option Selection (T/M)...6691
        [DAZ9KQ] A/C Model Selection Abnormality...6691
        [DAZQKR] CAN2 Discon (Aircon ECU)...6692
        [DB2QKR] CAN2 Discon (Engine Con)...6693
        [DB2RKR] CAN1 Discon (Engine Con)...6699
        [DB90KK] Drop in BBC Controller Main Power Source...6705
        [DB90KT] Abnormality of Non-Volatile Memory (BBC)...6707
        [DB90MC] BBC Error...6707
        [DB91KA] Disconnection of Key SW ACC (BBC)...6709
        [DB92KK] Solenoid Power Source Low (BBC)...6711
        [DB95KX] Failure of 5 V Power Source 1...6715
        [DB96KX] Failure of 5 V Power Source 2...6719
        [DB99KQ] Inconsistency of Model Selection (BBC)...6721
        [DB9LKA] Operating Lamp Open Circuit (BBC)...6723
        [DB9LKB] Operating Lamp Short Circuit (BBC)...6725
        [DB9QKR] CAN2 Discon (Bucket Boom Con)...6727
        [DB9RKR] CAN1 Discon (Bucket Boom Con)...6728
        [DB9RMA] Inconsistency of Option Selection (BBC)...6729
        [DBE5KX] Failure of 5 V Power Source...6731
        [DBE6KX] Failure of 24 V Power Source...6733
        [DD1ALD] Ground Fault of Remote Positioner Set SW...6735
        [DDAAL6] Disconnection of Secondary Switch ENG Stop SW...6737
        [DDB6L4] Neutral Signal Malfunction...6739
        [DDD1LD] Failure of Bucket Positioner Set Switch...6743
        [DDK3KA] FNR SW Input Signal Disconnection...6745
        [DDK3KB] FNR SW Input Signal Short Circuit...6749
        [DDK6KA] FNR Lever Input Signal Disconnection...6751
        [DDK6KB] FNR Lever Input Signal Short Circuit...6755
        [DDNRKY] Hot Short of Work Equipment Lock SW...6757
        [DDT0L4] Failure of Shift Mode Select SW...6759
        [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal...6761
        [DDT9LD] Ground Fault of T/M Cut Off Set SW Signal...6763
        [DDW9LD] Ground Fault of Kick-Down Switch...6765
        [DDWLLD] Ground Fault of T/M Shift Hold SW...6767
        [DF10KA] Disconnection of Shift Lever Input...6769
        [DF10KB] Ground Fault of Shift Lever Input...6773
        [DGF1KA] Disconnection of T/M Oil Temp Sensor...6777
        [DGF1KB] Ground Fault of T/M Oil Temp. Sensor...6779
        [DGH2KX] Out of Range of HYD Oil Temp. Sensor...6781
        [DGR2KB] Ground Fault of Brake Oil Temp. Sensor...6783
        [DGR2KZ] Failure of Brake Oil Temp. Sensor...6785
        [DGT1KA] Disconnection of T/C Oil Temp. Sensor...6787
        [DGT1KB] Ground Fault of T/C Oil Temp. Sensor...6789
        [DH21KA] Failure of Loader Pump Press. Sensor...6791
        [DH21KB] Loader Pump Press. Sensor Short Circuit...6795
        [DHA4KA] Failure of Air Cleaner Sensor Circuit...6797
        [DHPCKX] Out of Range of Boom Bottom Press. Sensor...6799
        [DHPDKX] Out of Range of Boom Head Press. Sensor...6801
        [DHT1KX] Out of Range of T/M Cut Off Press. Sensor...6803
        [DHT5KX] Out of Range of T/C Input Pressure Sensor...6805
        [DHT7KX] Out of Range of T/C Output Pressure Sensor...6807
        [DHT8KA] Failure of Steering Pump Press. Sensor...6809
        [DHT8KB] Steering Pump Press. Sensor Short Circuit...6811
        [DHT8ZG] Steering Oil Pressure Low...6813
        [DHUDKA] Failure of Emrg. Steering Press. Sensor...6815
        [DHUDKB] Emrg. Steering Press. S. Short Circuit...6819
        [DJF1KA] Disconnection of Fuel Level Sensor...6821
        [DK55KA] Failure of FNR Lever Potentio...6823
        [DK55KY] Hot Short of FNR Lever Potentio Circuit...6827
        [DK55L5] Failure of FNR Lever Potentio...6829
        [DK59KA] Failure of Boom Lever Potentio (Main)...6830
        [DK59KY] Hot Short of Boom Lever Potentio (Main)...6833
        [DK59L8] Boom Lever Potentio (Main & Sub) Disagree...6835
        [DK5AKA] Failure of Boom Lever Potentio (Sub)...6839
        [DK5AKY] Hot Short of Boom Lever Potentio (Sub)...6843
        [DK5BKA] Failure of Bucket Lever Potentio (Main)...6847
        [DK5BKY] Hot Short of Bucket Lever Potentio (Main)...6851
        [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree...6855
        [DK5CKA] Failure of Bucket Lever Potentio (Sub)...6859
        [DK5CKY] Hot Short of Bucket Lever Potentio (Sub)...6863
        [DK5DKA] Failure of 3rd Lever Potentio (Main)...6867
        [DK5DKY] Hot Short of 3rd Lever Potentio (Main)...6871
        [DK5DL8] 3rd Lever Potentio (Main&Sub) Disagree...6873
        [DK5EKA] Failure of 3rd Lever Potentio (Sub)...6877
        [DK5EKY] Hot Short of 3rd Lever Potentio (Sub)...6879
        [DK5KKA] Failure of 4th Lever Potentio (Main)...6881
        [DK5KKY] Hot Short of 4th Lever Potentio (Main)...6883
        [DK5KL8] 4th Lever Potentio (Main&Sub) Disagree...6885
        [DK5LKA] Failure of 4th Lever Potentio (Sub)...6889
        [DK5LKY] Hot Short of 4th Lever Potentio (Sub)...6891
        [DKA0KA] Failure of Boom Angle Sensor...6893
        [DKA0KY] Hot Short of Boom Angle Sensor Circuit...6895
        [DKA0L0] Boom Angle Sensor Dislocation...6897
        [DKA1KA] Failure of Bucket Angle Sensor...6899
        [DKA1KY] Hot Short of Bucket Angle Sensor Circuit...6901
        [DLF1KA] Disconnection of T/M Input Speed Sensor...6903
        [DLF1LC] Failure of T/M Input Speed Sensor...6905
        [DLM3KA] Disconnection of Radiator Fan Speed Sensor...6907
        [DLM3LC] Failure of Radiator Fan Speed Sensor...6909
        [DLT3KA] Disconnection of Output Speed Sens. (Main)...6911
        [DLT3LC] Failure of Output Speed Sensor (Main)...6913
        [DPQ1KR] LIN Discon (Switch Panel)...6915
        [DPQ2KR] LIN Discon (LED Unit)...6919
        [DPQ3KR] LIN DIscon (Rear View Monitor)...6923
        [DJS0KR] CAN2 Discon (Meter Unit)...6927
        [DT20KB] Ground Fault of T/M Cut Off Indicator...6929
        [DT22KB] Ground Fault of Work Equip. Lock Indic...6931
        [DV00KB] Ground Fault of Buzzer Output...6933
        [DW4PKA] Disconnection of Boom EPC Solenoid (Raise)...6935
        [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise)...6937
        [DW4PKY] Hot Short of Boom EPC Solenoid (Raise)...6939
        [DW4QKA] Disconnection of Boom EPC Solenoid (Lower)...6941
        [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower)...6943
        [DW4QKY] Hot Short of Boom EPC Solenoid (Lower)...6945
        [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt)...6947
        [DW4RKB] Ground Fault of Bucket EPC Sol. (Tilt)...6949
        [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt)...6951
        [DW4SKA] Disconnection of Bucket EPC. Sol (Dump)...6953
        [DW4SKB] Ground Fault of Bucket EPC Sol. (Dump)...6955
        [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump)...6957
        [DW7BKA] Disconnection of Fan Reverse Solenoid...6959
        [DW7BKB] Ground Fault of Radiator Fan Reverse Solenoid...6961
        [DW7BKY] Hot Short of Radiator Fan Rev. Sol...6963
        [DWM1KA] Disconnection of Neutral Lock Solenoid...6965
        [DWM1KB] Ground Fault of Neutral Lock Solenoid...6967
        [DWM1KY] Hot Short of Neutral Lock Solenoid...6969
        [DWN6KA] Disconnection of Detent Solenoid (Boom)...6971
        [DWN6KB] Ground Fault of Detent Solenoid (Boom)...6973
        [DWN6KY] Hot Short of Detent Solenoid (Boom)...6975
        [DWN8KA] Disconnection of Detent Solenoid (Bucket)...6977
        [DWN8KB] Ground Fault of Detent Solenoid (Bucket)...6979
        [DWN8KY] Hot Short of Detent Solenoid (Bucket)...6981
        [DX16KA] Disconnection of Radiator Fan Pump EPC Solenoid...6983
        [DX16KB] Ground Fault of Radiator Fan Pump EPC Solenoid...6985
        [DX16KY] Hot Short of Radiator Fan Pump EPC Solenoid...6987
        [DXA1KA] Disconnection of Loader Pump EPC Solenoid...6989
        [DXA1KB] Ground Fault of Loader Pump EPC Solenoid...6991
        [DXA1KY] Hot Short of Loader Pump EPC Solenoid...6993
        [DXANKA] Disconnection of Steering Pump EPC Solenoid...6995
        [DXANKB] Ground Fault of Steering Pump EPC Solenoid...6997
        [DXANKY] Hot Short of Steering Pump EPC Solenoid...6999
        [DXH1KA] Disconnection of ECMV Solenoid (Lockup)...7001
        [DXH1KB] Ground Fault of ECMV Solenoid (Lockup)...7003
        [DXH1KY] Hot Short of ECMV Solenoid (Lockup)...7005
        [DXH4KA] Disconnection of ECMV Solenoid (1st)...7007
        [DXH4KB] Ground Fault of ECMV Solenoid (1st)...7009
        [DXH4KY] Hot Short of ECMV Solenoid (1st)...7011
        [DXH5KA] Disconnection of ECMV Solenoid (2nd)...7013
        [DXH5KB] Ground Fault of ECMV Solenoid (2nd)...7015
        [DXH5KY] Hot Short of ECMV Solenoid (2nd)...7017
        [DXH6KA] Disconnection of ECMV Solenoid (3rd)...7019
        [DXH6KB] Ground Fault of ECMV Solenoid (3rd)...7021
        [DXH6KY] Hot Short of ECMV Solenoid (3rd)...7023
        [DXH7KA] Disconnection of ECMV Solenoid (Reverse)...7025
        [DXH7KB] Ground Fault of ECMV Solenoid (Reverse)...7027
        [DXH7KY] Hot Short of ECMV Solenoid (Reverse)...7029
        [DXH8KA] Disconnection of ECMV Solenoid (Forward)...7031
        [DXH8KB] Ground Fault of ECMV Solenoid (Forward)...7033
        [DXH8KY] Hot Short of ECMV Solenoid (Forward)...7035
        [DXHHKA] Disconnection of ECMV Solenoid (4th)...7037
        [DXHHKB] Ground Fault of ECMV Solenoid (4th)...7039
        [DXHHKY] Hot Short of ECMV Solenoid (4th)...7041
        [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT)...7043
        [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)...7045
        [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT)...7047
        [DXHKKA] Disconnection of 3rd EPC Solenoid (RET)...7049
        [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET)...7051
        [DXHKKY] Hot Short of 3rd EPC Solenoid (RET)...7053
        [DXJEKA] Disconnection of 4th EPC Solenoid (EXT)...7055
        [DXJEKB] Ground Fault of 4th EPC Solenoid (EXT)...7057
        [DXJEKY] Hot Short of 4th EPC Solenoid (EXT)...7059
        [DXJFKA] Disconnection of 4th EPC Solenoid (RET)...7061
        [DXJFKB] Ground Fault of 4th EPC Solenoid (RET)...7063
        [DXJFKY] Hot Short of 4th EPC Solenoid (RET)...7065
        [DY30MA] Malfunction 1 of Emerg. Steering Motor...7067
        [DY30MC] Malfunction 2 of Emerg. Steering Motor...7071
        [DY30ME] Emergency Steering Long-Time Activated...7075
        [H2K0KA] Failure of Quick Coupler Lock Signal...7079
        [H2K0KY] Hot Short of Quick Coupler Lock Signal...7082
        [LA00L3] Failure of Fan Reverse...7085
      TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...7087
        E-1 Engine Does Not Start...7087
        E-2 Manual Preheating System Does Not Work...7095
        E-3 Automatic Preheating System Does Not Work...7099
        E-4 While Preheating is Working, Preheating Monitor Does Not Light Up...7101
        E-5 All of LCD Unit, LED Unit, and Meter Unit on Machine Monitor Display Nothing...7103
        E-6 LCD Unit on Machine Monitor Displays Nothing...7107
        E-7 Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Out or Flickers)...7109
        E-8 LCD on Machine Monitor Does Not Display Properly...7111
        E-9 Meter Unit Display on Machine Monitor is Abnormal...7113
        E-10 Night Lighting Lamp of Meter Unit on Machine Monitor is Abnormal...7117
        E-11 Caution LED on Machine Monitor is Abnormal...7121
        E-12 LED of Switch Panel on Machine Monitor is Abnormal or Switches Does Not Operate Properly...7125
        E-13 Two Switches Operation of Switch Panel on Machine Monitor Does Not Function...7129
        E-14 Switch Panel Buzzer of Machine Monitor is Abnormal...7133
        E-15 Rear View Monitor Does Not Light Up or Backlight Flickers...7137
        E-16 Rear View Monitor Images are not Displayed Clearly...7141
        E-17 Rear View Monitor Brightness cannot be Adjusted...7145
        E-18 Night Lighting Lamp of Rear View Monitor is Abnormal...7149
        E-19 Some Items of Gauges and Caution Lamps on Machine Monitor are not Displayed Properly...7152
        E-20 Parking Brake Indicator Lamp does not Light When the Parking Brake is Set to ON (Parking) Position...7153
        E-21 When Brake Accumulator Oil Pressure Drops, the Brake Oil Pressure Caution Lamp does not Light...7157
          Front Brake...7157
          Rear Brake...7159
        E-22 Air Cleaner Clogging Indicator Lamp does not Light...7161
        E-23 Radiator Coolant Level Caution Lamp does not Light...7163
        E-24 Indication of Hydraulic Oil Temperature Gauge does not Increase, or Hydraulic Oil Temperature Caution Lamp does not Light...7165
        E-25 Indication of Torque Converter Oil Temperature Gauge does not Increase, or Torque Converter Oil Temperature Caution Lamp does not Light...7166
        E-26 Fuel Level Gauge does not Indicate Correct Level...7167
        E-27 Seat Belt Caution Lamp Indication is Abnormal...7169
        E-28 Horn does not Sound...7171
        E-29 Horn does not Stop Sounding...7175
        E-30 Alarm Buzzer does not Sound...7177
        E-31 When Starting Switch is in ON Position, Alarm Buzzer does not Stop Sounding...7179
        E-32 Kick-Down does not Work when kick-Down Switch is Turned ON...7181
        E-33 The Hold Switch does not Work When it is Pressed...7183
        E-34 Parking Brake does not Work Even if it is Applied, or the Brake Drags When Parking Brake is Released and FR Drive is Operated...7185
        E-35 Transmission Cut-Off Mode is not Selected or not Released...7189
        E-36 Transmission Cut-Off Setting cannot be Released...7191
        E-37 Directional Selector (FNR) Switch Mode is not Selected or not Released...7193
        E-38 When Operating Engine Power Selection Switch, Engine Power Selection Function does not Operate Properly...7195
        E-39 Flow of Loader Pump does not Increase from the Minimum Rate...7197
        E-40 ECSS Function cannot be Selected or cannot be Released...7199
        E-41 None of Headlamp, Clearance Lamp, and Tail Lamp Light...7201
        E-42 Clearance Lamp and Tail Lamp do not Light Up or go Out...7203
        E-43 Both "High and Low Beams" of Headlamp do not Light Up or Go Out...7207
        E-44 The Headlamp "Low Beam" does not Light Up or Go Out...7211
        E-45 The Headlamp "High Beam" does not Light Up or Go Out...7213
        E-46 Front Working Lamp does not Light Up or Go Out...7215
        E-47 Rear Working Lamp does not Light Up or Go Out...7219
        E-48 All of Turn Signal Lamps and Hazard Lamps do not Light Up or Go Out...7223
        E-49 Turn Signal Lamps do not Light Up or Go Out...7227
        E-50 Hazard Lamp does not Light Up or Go Out...7231
        E-51 Brake Lamp does not Light Up or Stays Lighted...7235
        E-52 Back-Up Lamp does not Light or Continues To Light...7239
        E-53 Back-Up Buzzer does not Sound or Continues to Sound...7243
        E-54 Front Wiper does not Operate...7245
        E-55 Rear Wiper does not Operate...7249
        E-56 Window Washer does not Operate...7253
        E-57 KOMTRAX System does not Operate Properly...7257
      TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...7259
        Information Mentioned in Troubleshooting Table (H-mode)...7259
        System Chart of Hydraulic and Mechanical Systems...7260
        Failure Mode and Cause Table...7263
        H-1 Machine Does Not Start...7273
        H-2 Torque Converter Lockup is Not Disengaged (Engine Stalls)...7277
        H-3 Torque Converter Lockup Clutch is Not Engaged...7277
        H-4 Travel Speed is Slow, Bucket Thrusting Force is Weak, Gradability is Low, or Gear Speed Does Not Shift...7278
        H-5 Large Shock is Made When Machine Starts or Gear is Shifted...7281
        H-6 Machine Starts or Gear Speed Shifts with Long Time Lag...7285
        H-7 Torque Converter Oil Temperature is High...7289
        H-8 Machine Does Not Turn...7293
        H-9 Turning Response is Poor...7295
        H-10 Steering Wheel is Heavy to Turn...7297
        H-11 Machine Sways or Large Shocks Are Made While Machine Turns...7299
        H-12 Turning Radius Differs Between Right and Left Turns...7301
        H-13 Wheel Brakes Do Not Work or Are Weak...7303
        H-14 Wheel Brakes Are Not Released or Drag...7305
        H-15 Parking Brake Does Not Work or It is Weak...7305
        H-16 Parking Brake is Not Released or It Drags (Including Emergency Release System)...7306
        H-17 Boom Does Not Rise...7307
        H-18 Boom Moves Slow or Boom Lacks Lifting Force...7309
        H-19 Rising Boom Slows Down at Certain Height...7311
        H-20 Boom Cylinders Do Not Serve to Hold Bucket on Ground...7312
        H-21 Hydraulic Drift of Boom is Large...7313
        H-22 Boom Moves Up and Down During Operation...7314
        H-23 Bucket Does Not Tilt Back...7315
        H-24 Bucket Moves Slow or Bucket Lacks Tilt-Back Force...7317
        H-25 Bucket Decelerates During Tilt-Back Operation...7319
        H-26 Bucket Cylinder Does Not Hold Bucket on Ground...7321
        H-27 Hydraulic Drift of Bucket is Large...7322
        H-28 Bucket Tilts Back and Forth During Carrying Load (Work Equipment Valve in “Hold”)...7323
        H-29 Boom and Bucket Control Levers Do Not Move Smoothly and Heavy to Move...7324
        H-30 Operating Work Equipment Causes Engine Speed to Lower Significantly or Engine to Stall...7325
        H-31 Large Shocks Are Made When Work Equipment Starts to Move and Stops...7327
        H-32 When Certain Work Equipment Stalls Hydraulically, Other Work Equipment Moves...7328
        H-33 E.C.S.S. (Travel Damper) Does Not Work and Machine Pitches and Bounces...7329
        H-34 Air Conditioner Does Not Work While Cooling Fan Rotates in Reverse Mode...7330
        H-35 Fan Speed is Abnormal (Too High or Low, or Fan Does Not Rotate)...7331
        H-36 Unusual Noise is Heard from Around Fan...7332
      TROUBLESHOOTING OF ENGINE (S-MODE)...7333
        Information Mentioned in Troubleshooting Table (S-Mode)...7333
        S-1 When Starting Switch is Turned to START Position, Engine Does Not Crank...7334
        S-2 When Engine Cranks, but No Exhaust Smoke Comes Out...7335
        S-3 Fuel is Being Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)...7336
        S-4 Engine Startability is Poor...7338
        S-5 Engine Does Not Pick Up Smoothly...7340
        S-6 Engine Stops During Operation...7342
        S-7 Engine Runs Rough or is Unstable...7344
        S-8 Engine Lacks Power...7345
        S-9 Exhaust Smoke is Black (KDPF Clogs Up Early)...7348
        S-10 Engine Oil Consumption is Excessive...7350
        S-11 Oil Becomes Contaminated Quickly...7351
        S-12 Fuel Consumption is Excessive...7352
        S-13 Oil is in Coolant (or Coolant Spurts or Coolant Level Goes Down)...7353
        S-14 Engine Oil Pressure Drops...7354
        S-15 Fuel Mixes in Engine Oil...7356
        S-16 Water mixes into Engine Oil (Milky)...7357
        S-17 Coolant Temperature Rises Too High (Overheating)...7358
        S-18 Unusual Noise is Heard...7359
        S-19 Vibration is Excessive...7360
        S-20 Air Cannot Be Bled From Circuit...7361
        S-21 Active Regeneration is Executed Frequently...7362
        S-22 Active Regeneration Takes Time...7363
        S-23 White Smoke is Exhausted During Active Regeneration...7364
    50 DISASSEMBLY AND ASSEMBLY...7366
      HOW TO READ THIS SECTION...7371
        Removal and Installation of Assemblies...7371
          Special Tools...7371
          Removal...7371
          Installation...7371
        Disassembly and Assembly of Assemblies...7372
          Special Tools...7372
          Disassembly...7372
          Assembly...7372
      COATING MATERIALS LIST...7373
      SPECIAL TOOLS LIST...7377
      SKETCHES OF SPECIAL TOOLS...7381
      CONNECTOR REPAIR PROCEDURES...7389
        Stripping Insulation...7389
        Wire Inspection...7389
        Contact Terminal Removal (HD30 Type)...7390
        Crimping Contact Terminal (HD30 Type)...7391
        Insertion Of Contact Terminal (HD30 Type)...7392
        Contact Terminal Removal (DT Type)...7393
        Crimping Contact Terminal (DT Type)...7394
        Insertion Of Contact Terminal (DT Type)...7395
      ENGINE AND COOLING SYSTEM...7396
        Supply Pump Assembly...7396
          Removal...7396
          Installation...7399
        Injector Assembly...7401
        Special Tools...7401
          Removal...7401
          Installation...7408
        Cylinder Head Assembly...7415
          Removal...7415
          Installation...7425
        Engine Hood...7441
          Removal...7441
          Installation...7444
        Grille Assembly...7445
          Removal...7445
          Installation...7446
        Cooling System Assembly...7447
          Removal...7447
          Installation...7449
        Radiator Core Assembly...7451
          Removal...7451
          Installation...7454
        After Cooler...7455
          Removal...7455
          Installation...7456
        Hydraulic Oil Cooler...7457
          Removal...7457
          Installation...7457
        Fuel Cooler Assembly...7458
          Removal...7458
          Installation...7458
        Engine, Torque Converter and Transmission Assemblies...7459
          Removal...7459
          Installation...7467
        Disconnect and Connection of Engine, Torque Converter and Transmission Assembly...7471
          Disconnection...7471
          Connection...7472
        Engine Front Oil Seal...7473
          Removal...7473
          Installation...7475
        Engine Rear Oil Seal...7477
          Removal...7477
          Installation...7478
        Cooling Fan and Fan Motor Assembly...7481
          Removal...7481
          Installation...7482
        KDPF Assembly...7483
          Removal...7483
          Installation...7486
        Disassembly and Assembly of KDPF Assembly...7487
          Disassembly...7487
          Assembly...7493
        KCCV Assembly...7499
          Removal...7499
          Installation...7499
        Air Cleaner Assembly...7501
          Removal...7501
          Installation...7503
        Fuel Tank...7505
          Removal...7505
          Installation...7508
      POWER TRAIN...7509
        Disassembly and Assembly of Torque Converter Assembly...7509
          Disassembly...7509
          Assembly...7512
        Transmission...7519
          Disassembly...7519
          Assembly...7526
        Transmission Clutch Pack Assembly...7537
          Disassembly...7537
          Assembly...7545
        Differential Assembly...7558
          Disassembly...7558
          Assembly...7567
        Parking Brake...7583
          Disassembly...7583
          Assembly...7586
        Front Axle...7593
          Removal...7593
          Installation...7594
        Rear Axle...7595
          Removal...7595
          Installation...7597
        Axle Housing...7600
          Disassembly...7600
          Assembly...7605
      STEERING SYSTEM...7613
        Steering Valve Assembly...7613
          Removal...7613
          Installation...7614
      BRAKE SYSTEM...7615
        Parking Brake Discs and Plates...7615
          Removal...7615
          Drain the oil from the transmission case...7615
          Installation...7617
      UNDERCARRAGE AND FRAME...7619
        Center Hinge Pin...7619
          Installation...7624
        Counterweight...7629
          Removal...7629
          Installation...7630
        Full-Length Fender Assembly...7631
          Removal...7631
          Installation...7632
      HYDRAULIC SYSTEM...7633
        Hydraulic Tank Assembly...7633
          Removal...7633
          Installation...7636
        Work Equipment Control Valve...7637
          Removal...7637
          Installation...7641
        Power Train Pump and Work Equipment Pump Assembly...7643
          Removal...7643
          Installation...7644
        Steering Pump And Cooling Fan Pump Assembly...7645
          Installation...7646
        Hydraulic Cylinder...7647
          Disassembly...7647
          Assembly...7651
      WORK EQUIPMENT...7657
        Work Equipment Assembly...7657
          Removal...7657
          Installation...7661
      CAB AND ATTACHMENTS...7665
        Cab and Floor Frame...7665
          Removal...7665
          Installation...7669
        Cab Glass (Stuck Window Glass)...7671
          Removal...7671
          Installation...7672
        Operator Seat Assembly...7680
          Removal...7680
          Installation...7681
        Seat Belt...7682
          Removal...7682
          Installation...7682
      ELECTRICAL SYSTEM...7683
        Machine Monitor Assembly...7683
          Removal...7683
          Installation...7683
        Engine Controller Assembly...7684
          Removal...7684
          Installation...7684
        Work Equipment Controller Assembly...7686
          Removal...7686
          Installation...7687
        Transmission Controller Assembly...7688
          Removal...7688
          Installation...7688
        Monitor Controller Assembly...7689
          Removal...7689
          Installation...7691
        Mass Air Flow and Temperature Sensor...7693
          Removal...7693
          Installation...7693
        KOMTRAX Terminal Assembly...7694
          Removal...7694
          Installation...7694
    60 MAINTENANCE STANDARD...7696
      ENGINE AND COOLING SYSTEM...7699
        Engine Related Parts...7699
        Cooling Fan Clamp...7701
        Servo Valve...7703
        Cooling Fan Motor...7705
      POWER TRAIN...7707
        Drive Shaft...7707
        Torque Converter...7708
        Transmission...7711
        Forward and Reverse Clutches...7717
        1st and 4th Clutches...7718
        2nd and 3rd Clutches...7719
        Transmission Control Valve...7721
        Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV...7723
        Lockup Clutch ECMV...7724
        Main Relief and Torque Converter Relief Valve...7725
        Differential...7727
          Front Differential (Standard: Conventional Differential)...7727
          Rear differential (Standard: Conventional Differential)...7729
        Limited Slip Differential...7731
          Front Axle...7731
          Rear Axle...7733
        Final Drive...7735
      STEERING SYSTEM...7737
        Steering Column...7737
        Steering Pump...7738
        Pump Body...7739
        Servo Valve...7741
        Steering Valve...7742
        Steering Cylinder...7743
        Emergency Steering Pump (if equipped)...7745
        Brake System...7747
          Charge Valve...7747
        Brakes...7749
          Front Brake...7749
          Rear Brake...7750
          Parking Brake...7751
          Parking Brake Solenoid Valve...7752
      UNDERCARRIAGE AND FRAME...7753
        Axle Mount and Center Hinge Pin...7753
      HYDRAULIC SYSTEM...7757
        Hydraulic Tank...7757
        Double Type Gear Pump...7758
          Power Train Charge Pump and Power Train Lubrication Pump...7758
      WORK EQUIPMENT PUMP...7760
        Pump Body...7761
        Servo Valve...7763
      CONTROL VALVE...7765
      STABILIZER VALVE...7777
      WORK EQUIPMENT...7779
        Work Equipment Linkage...7779
      BUCKET...7781
      WORK EQUIPMENT CYLINDER...7783
        Boom Cylinder...7783
        Bucket Cylinder...7783
    80 AIR CONDITIONING...7784
      AIR CONDITIONER...7787
        Precautions for Refrigerant...7787
        Air Conditioner Component...7789
        Structure and Function of Refrigeration System...7791
        Overview of Refrigeration System...7792
        Air Conditioner Unit...7795
          Function...7796
        Functions of Major Components...7798
          Evaporator...7798
          Heater Core...7798
          Evaporator Temperature Sensor...7798
          Inner Sensor...7798
          Blower Amplifier...7798
          Blower Off Relay...7798
          Compressor Clutch Relay...7798
          Servomotor...7799
          Expansion Valve...7800
          Dual Pressure Switch...7800
          Air Conditioner Controller...7800
          Compressor...7801
          Condenser...7802
          Receiver...7803
          Sunlight Sensor...7804
        Outside Air Temperature Sensor...7804
        Inspection and Troubleshooting Procedure of Air Conditioner...7804
          Basic Inspection and Troubleshooting Sequence...7805
        Air Conditioner Circuit Diagram and Arrangement of Connector Pins...7807
        System Diagram...7809
        Parts and Connectors Layout...7811
        Testing with Self-Diagnosis Function...7816
        How to Enter Air Conditioner “Electrical Systems” Screen in Service Mode of the Machine Monitor...7817
        Testing Temperature Control System...7819
          Testing...7819
        Testing Vent (Mode) Changeover...7821
          Testing...7821
        Testing FRESH/RECIRC Air Changeover...7823
        Testing Relay...7824
        Troubleshooting Chart 1...7825
        Troubleshooting Chart 2...7826
        Information Mentioned in Troubleshooting Table...7829
          Information in Troubleshooting Table...7829
        Troubleshooting with Gauge Pressure...7831
        Testing Refrigerant Pressure...7835
        Precautions for Disconnecting and Connecting Refrigerant Piping...7837
          Disconnection...7837
          Connection...7837
        Filling Compressor Oil...7839
    90 DIAGRAMS AND SCHEMATICS...7842
      HYDRAULIC SYSTEM...7844
        Hydraulic Circuit Diagram...7847
        Power Train Hydraulic Circuit Diagram...7848
      ELECTRICAL SYSTEM...7850
        Symbols in Electrical Circuit Diagram...7850
        Electrical Circuit Diagram (1/5)...7854
        Electrical Circuit Diagram (2/5)...7855
        Electrical Circuit Diagram (3/5)...7856
        Electrical Circuit Diagram (4/5)...7857
        Electrical Circuit Diagram (5/5)...7858
        Electrical Circuit Floor Diagram (1/8)...7859
        Electrical Circuit Floor Diagram (2/8)...7860
        Electrical Circuit Floor Diagram (3/8)...7861
        Electrical Circuit Floor Diagram (4/8)...7862
        Electrical Circuit Floor Diagram (5/8)...7863
        Electrical Circuit Floor Diagram (6/8)...7864
        Electrical Circuit Floor Diagram (7/8)...7865
        Electrical Circuit Floor Diagram (8/8)...7866
        Electrical Circuit Air Conditioner Diagram...7867
CEBMW23091 - Wheel Loader WA380-3 Shop Manual...7868
  CONTENTS...7869
  01 GENERAL...7891
    SPECIFICATION DRAWINGS...7892
    SPECIFICATIONS...7893
    WEIGHT TABLE...7896
    FUEL, COOLANT AND LUBRICANTS...7897
    ENGINE OIL SPECIFICATIONS...7898
    DIESEL FUEL SPECIFICATIONS...7899
    COOLANT SPECIFICATIONS...7900
  10 STRUCTURE AND FUNCTION...7905
    POWER TRAIN...7906
    POWER TRAIN SYSTEM...7907
    TORQUE CONVERTER, TRANSMISSION PIPING...7909
    TRANSMISSION HYDRAULIC SYSTEM DIAGRAM...7910
    TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM...7911
    TORQUE CONVERTER...7912
    TORQUE CONVERTER OIL FILTER...7914
    TRANSMISSION...7915
    TRANSMISSION CONTROL VALVE...7926
    DRIVE SHAFT...7950
    AXLE...7951
    DIFFERENTIAL...7953
    FINAL DRIVE...7957
    AXLE MOUNT, CENTER HINGE PIN...7958
    STEERING PIPING...7960
    STEERING COLUMN...7961
    STEERING VALVE...7962
    ORBIT-ROLL VALVE...7976
    STOP VALVE...7980
    EMERGENCY STEERING PUMP...7981
    DIVERTER VALVE...7982
    BRAKE PIPING...7985
    BRAKE HYDRAULIC CIRCUIT DIAGRAM...7986
    BRAKE VALVE...7987
    ACCUMULATOR CHARGE VALVE...7992
    ACCUMULATOR (FOR BRAKE)...7996
    BRAKE...7998
    PARKING BRAKE CONTROL...8000
    PARKING BRAKE...8001
    PARKING BRAKE SOLENOID VALVE...8002
    PARKING BRAKE VALVE...8003
    PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE...8004
    HYDRAULIC PIPING...8005
    WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM...8007
    WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...8008
    STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...8009
    WORK EQUIPMENT LEVER LINKAGE...8010
    HYDRAULIC TANK...8011
    PPC VALVE...8013
    PPC RELIEF VALVE...8018
    ACCUMULATOR (FOR PPC VALVE)...8019
    MAIN CONTROL VALVE...8020
    WORK EQUIPMENT LINKAGE...8035
    BUCKET...8037
    BUCKET POSITIONER AND BOOM KICK-OUT...8038
    CAB...8044
    AIR CONDITIONER...8045
    ELECRIC CIRCUIT DIAGRAM...8046
    ELECTRIC CIRCUIT DIAGRAM (1/4)...8047
    ELECTRIC CIRCUIT DIAGRAM (2/4)...8048
    ELECTRIC CIRCUIT DIAGRAM (3/4)...8049
    ELECTRIC CIRCUIT DIAGRAM (4/4)...8050
    ELECTRIC CIRCUIT DIAGRAM...8051
    ELECTRIC CIRCUIT DIAGRAM...8052
    MACHINE MONITOR SYSTEM...8053
    MAIN MONITOR...8054
    MAINTENANCE MONITOR...8058
    TRANSMISSION AUTO-SHIFT CONTROL SYSTEM...8061
    E.C.S.S. (ELECTRONICALLY CONTROL SUSPENSION SYSTEM)...8068
    SENSORS...8072
    ENGINE STARTING CIRCUIT...8076
    ENGINE STOP CIRCUIT...8077
    ETHER START CIRCUIT...8078
    ELECTRIC TRANSMISSION CONTROL...8079
    KICK-DOWN, HOLD SWITCH...8082
    KICK-DOWN ELECTRIC CIRCUIT DIAGRAM...8083
    TRANSMISSION CUT-OFF FUNCTION...8088
    ELECTRIC PARKING BRAKE CONTROL...8090
  20 STRUCTURE AND FUNCTION...8102
    STANDARD VALUE TABLE FOR ENGINE...8103
    STANDARD VALUE TABLE FOR CHASSIS...8104
    STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM...8108
    SERVICE TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING...8112
    MEASURING ENGINE SPEEDS...8113
    MEASURING INTAKE MANIFOLD PRESSURE...8113
    MEASURING INTAKE AIR RESTRICTION...8113
    MEASURING LUBRICATING OIL PRESSURE...8114
    MEASURING FUEL FILTER INLET RESTRICTION...8114
    MEASURING BLOW-BY PRESSURE...8114
    MEASURING EXHAUST BACK PRESSURE...8115
    MEASURING EXHAUST GAS COLOR...8116
    MEASURING COOLANT TEMPERATURE...8117
    MEASURING AND ADJUSTING VALVE CLEARANCE...8117
    MEASURING WASTEGATE ACTUATOR CALIBRATION...8117
    MEASURING STALL SPEEDS...8118
    MEASURING ACCELERATOR PEDAL...8120
    MEASURING OPERATING FORCE & TRAVEL OF DIRECTIONAL & SPEED LEVERS...8122
    MEASURING TORQUE CONVERTER, TRANSMISSION, PARKING BRAKE OIL PRESSURE...8123
    METHOD OF OPERATING EMERGENCY MANUAL SPOOL...8125
    MEASURING CLEARANCE BETWEEN TIRE AND WHEEL...8127
    TESTING AND ADJUSTING STEERING WHEEL...8128
    TESTING AND ADJUSTING STEERING CONTROL...8131
    MEASURING STEERING OIL PRESSURE...8132
    MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL...8134
    MEASURING BRAKE PERFORMANCE...8135
    TESTING BRAKE OIL PRESSURE...8136
    TESTING FOR BRAKE DISC WEAR...8137
    BLEEDING AIR FROM BRAKE SYSTEM...8138
    MEASURING PARKING BRAKE PERFORMANCE...8139
    MANUAL RELEASE METHOD FOR PARKING BRAKE...8140
    TESTING WEAR OF PARKING BRAKE DISC...8141
    MEASURING WORK EQUIPMENT CONTROL LEVER...8142
    MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE...8144
    MEASURING PPC VALVE PRESSURE...8146
    MEASURING WORK EQUIPMENT...8148
    TESTING AND ADJUSTING BUCKET POSITIONER...8150
    TESTING AND ADJUSTING BOOM KICK-OUT...8151
    ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)...8153
    TROUBLESHOOTING...8154
      POINTS TO REMEMBER WHEN TROUBLESHOOTING...8155
      SEQUENCE OF EVENTS IN TROUBLESHOOTING...8156
      PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...8157
      HANDLING CONNECTORS...8164
      CHECKS BEFORE TROUBLESHOOTING...8165
      METHOD OF USING TROUBLESHOOTING CHARTS...8166
      TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...8174
        S-1 Starting performance is poor (Starting always takes time)...8175
        S-2 Engine does not start...8176
          (1) Engine does not turn...8176
          (2) Engine turns but no exhaust gas comes out (Fuel is not being injected)...8177
          (3) Exhaust gas comes out but engine does not start (Fuel is being injected)...8178
        S-3 Engine does not pick up smoothly (Follow-up is poor)...8179
        S-4 Engine stops during operations...8180
        S-5 Engine does not rotate smoothly (hunting)...8181
        S-6 Engine lacks output (no power)...8182
        S-7 Exhaust gas is black (incomplete combustion)...8183
        S-8 Oil consumption is excessive (or exhaust gas is blue)...8184
        S-9 Oil becomes contaminated quickly...8185
        S-10 Fuel consumption is excessive...8186
        S-11 Oil is in cooling water, or water spurts back, or water level goes down...8187
        S-12 Oil pressure lamp lights up (drop in oil pressure)...8188
        S-13 Oil level rises...8189
        S-14 Water temperature becomes too high (overheating)...8190
        S-15 Abnormal noise is made...8191
        S-16 Vibration is excessive...8192
      TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)...8193
        TROUBLE DATA DISPLAY...8195
        M-1 Main monitor does not work...8197
        M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up...8198
        M-3 Speedometer display does not work properly...8199
        M-4 Abnormality in shift indicator...8200
          (a) Stays at N even when directional lever is at F...8200
          (b) Stays at N even when directional lever is at R...8200
          (c) Does not display N even when directional lever is at N and displays R when directional lever is at F...8200
          (d) Does not display N even when directional lever is at N and displays F when directional lever Cause Remedy...8201
          (e) Does not display lst, 4th...8201
          (f) Does not display 3rd, 4th...8201
          (g) Does not display 2nd, 3rd...8202
          (h) Does not display 1st 2nd...8202
        M-5 High beam does not light up...8203
        M-6 Turn signal display does not light up...8204
          (a) L.H. turn signal does not light up...8204
          (b) R.H. turn signal does not light up...8204
        M-7 Abnormality in parking display...8205
          (a) Parking lamp does not light up...8205
          (b) Parking lamp stays lighted up...8205
      TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)...8223
        K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 seconds, maintenance monitor does...8224
          (a) All lamps on maintenance monitor do not light up for 3 seconds...8224
          (b) Some lamps do not light up...8225
        K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out...8225
        K-3 When engine is started immediately after starting switch is turned...8226
        K-4 When starting switch is turned ON (engine stopped), CHECK items flash...8227
          (a) Engine oil level display flashes...8227
          (b) Engine water level display flashes...8228
        K-5 When starting switch is turned ON (engine started), CAUTION items flash...8229
          (a) Engine oil pressure display flashes...8229
          (b) Battery charge level display flashes...8230
          (c) Brake oil pressure display flashes...8231
          (d) Air cleaner display flashes...8232
        K-6 CAUTION items are flashing but alarm buzzer does not sound...8233
        K-7 There is no abnormality in monitor display but alarm buzzer sounds...8234
        K-8 CAUTION items are flashing but warning lamp (CHECK CAUTION lamp) does not light up lamp,...8235
          (a) CHECK lamp...8235
          (b) CAUTION lamp...8235
        K-9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up...8236
          (a) CHECK lamp...8236
          (b) CAUTION lamp...8236
        K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance monitor does not light up)...8237
        K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays lighted up...8238
        K-12 Service meter does not work...8239
        K-13 Service meter is running even when engine is stopped...8239
        K-14 Abnormality in gauge items...8240
          (a) Abnormality in fuel gauge...8240
          (b) Abnormality in engine water temperature gauge...8241
          (c) Abnormality in torque converter oil temperature gauge...8242
      TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...8243
        E-1 Engine does not start...8244
          (a) Starting motor does not turn...8244
          (b) Starting motor turns...8248
        E-2 Engine does not stop...8250
        E-3 Engine stops when machine is traveling...8250
        E-4 Parking brake does not work...8251
          (a) Parking brake has no effect when parking brake switch is turned ON (parking)...8251
          (b) Parking brake has no effect when brake pressure drops (Does not work as emergency brake)...8251
        E-5 Parking brake is applied when machine is traveling...8252
        E-6 Parking brake is released when starting switch is turned ON...8254
        E-7 Transmission does not change when parking brake is applied to neutral when parking brake is applied...8254
        E-8 Transmission does not work normally...8255
          (a) Problem in common circuit for transmission (always stays in 2nd)...8257
          (b) Problem in H-L circuit...8257
          (c) Problem in speed circuit...8258
          (d) Problem in 4th circuit (does not enter 4th)...8258
          (e) Contact in H-L circuit...8259
          (f) Contact in speed circuit...8261
          (g) Contact in 4th circuit (always stays in 4th)...8263
          (h) Problem in FORWARD circuit (REVERSE is normal)...8264
          (i) Problem in REVERSE circuit (FORWARD is normal)...8266
          (j) Problem in common circuit for FORWARD and REVERSE (does not travel forward, parking brake is normal)...8268
          (k) Contact in FORWARD circuit...8270
          (I) Contact in REVERSE circuit...8272
          (m) Problem in common circuit for FORWARD and REVERSE...8274
        E-9 Kick-down switch does not work (the regular F1 to F4 shifts normally)...8275
        E-10 Kick-down works only when kick-down switch is ON (Kick-down switch relay does not hold in position (self-holding function)...8277
        E-11 Kick-down operation cannot be canceled...8277
          (a) Not canceled even when directional lever is moved from F to N or R...8277
          (b) Not canceled even when speed lever is moved from 2nd to other position (becomes 4th)...8278
        E-12 Kick-down switch is actuated by mistake when traveling in 2nd...8280
      TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE)...8281
        POWER TRAIN...8282
          T-1 Machine does not start...8282
          T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes...8284
          T-3 Excessive shock when starting machine or shifting gear...8286
          T-4 Excessive time lag when starting machine or shifting...8287
          T-5 Torque converter oil temperature is high...8288
        STEERING SYSTEM...8289
          T-6 Steering does not turn...8289
          T-7 Steering wheel is heavy...8290
          T-8 Steering wheel wobbles or there is excessive shock...8291
          T-9 Machine steers to one side when traveling...8291
          T-10 Turning radius to left and right is different...8291
        BRAKE SYSTEM...8292
          T-11 Brakes do not work or braking effect is poor...8292
          T-12 Brakes are not released or brakes drag...8293
          T-13 Parking brake is not released or brake drags...8294
        WORK EQUIPMENT...8295
          T-14 Boom does not rise...8295
          T-15 Boom movement is slow or boom lacks lifting power...8296
          T-16 When boom is raised, it moves slowly at a certain height...8297
          T-17 Bucket cannot be pushed with boom cylinder (bucket floats)...8297
          T-18 Excessive hydraulic drift of boom...8297
          T-19 Boom shakes during operation...8297
          T-20 Boom drops momentarily when control lever is operated from HOLD to RAISE...8298
          T-21 Bucket does not tilt back...8299
          T-22 Bucket movement is slow or tilt-back lacks power...8300
          T-23 Bucket movement becomes slow during tilt-back operation...8301
          T-24 Bucket cannot be pushed with bucket cylinder...8301
          T-25 Excessive hydraulic drift of bucket...8301
          T-26 Bucket shakes during loading operation (Main control valve at HOLD)...8302
          T-27 Bucket dumps momentarily when control lever is operated from HOLD to TILT...8302
          T-28 Boom, bucket control levers are heavy or do not move smoothly...8303
      TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE)...8304
        JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM...8305
        D-1 ECSS does not work...8306
          (a) Error code [d0] is displayed...8307
          (b) Error code [d1] is displayed...8307
          (c) Error code [d2] is displayed...8308
          (e) Error code [d4] is displayed...8309
          (f) No abnormality display is given...8309
        D-2 ECSS cannot be canceled...8313
        D-3 Output is turned ON (travel speed does not become 5 km/h) (deviates around 5 km/h)...8314
        D-4 Output is turned ON when transmission is in 1st...8314
        D-5 Output is turned ON when transmission is in 4th...8315
        D-6 Controller LED code is not displayed...8316
        D-7 ECSS is abnormal but main monitor does not give abnormality display...8316
      TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)...8317
        OUTLINE...8318
        1. Function...8318
        2. When carrying out troubleshooting...8318
        3. Failure code table...8318
        4. Table of troubleshooting modes and causes...8319
        A-1 Troubleshooting code [10] Modulation valve solenoid system (disconnection, short circuit)...8320
        A-2 Troubleshooting code [11] Short circuit in power source for modulation valve solenoid system...8321
        A-3 Troubleshooting code [12] F solenoid signal system...8322
        A-4 Troubleshooting code [13] R solenoid signal system...8322
        A-5 Troubleshooting code [14] Abnormality system in H-L solenoid signal...8323
        A-6 Troubleshooting code [16] Abnormality in speed solenoid signal system...8324
        A-7 Troubleshooting code [17] Brake output signal...8325
        A-8 Troubleshooting code [20] Abnormality in directional lever signal system...8326
        A-9 Troubleshooting code [21] Abnormality in speed lever signal system...8327
        A-10 Troubleshooting code [22] Abnormality in travel speed signal...8328
        A-11 Troubleshooting code [23] Abnormality in engine speed signal...8329
        A-12 Hold switch system...8330
        A-13 Kick-down switch system...8330
        A-14 Kick-down output signal system...8331
        A-15 Transmission cut-off signal system...8332
        A-16 Neutralizer signal system...8333
        A-17 Buzzer signal system...8334
        A-18 Network signal system...8335
        A-19 Controller power source system...8336
        A-20 Abnormality in model selection wiring harness...8337
      TROUBLESHOOTING OF EAGLE AIR CONDITIONER...8338
  30 DISASSEMBLY AND ASSEMBLY...8342
    METHOD OF USING MANUAL...8344
    PRECAUTIONS WHEN CARRYING OUT OPERATION...8345
    SPECIAL TOOL LIST...8347
    STARTING MOTOR...8349
      REMOVAL AND INSTALLATION (SEE ENGINE SHOP MANUAL)...8349
    ENGINE OIL COOLER...8351
      REMOVAL AND INSTALLATION (SEE ENGINE SHOP MANUAL)...8351
    FUEL INJECTION PUMP...8352
      REMOVAL (SEE ENGINE SHOP MANUAL)...8352
      INSTALLATION (SEE ENGINE SHOP MANUAL)...8353
    WATER PUMP...8354
      REMOVAL AND INSTALLATION (SEE ENGINE SHOP MANUAL)...8354
    TURBOCHARGER...8355
      REMOVAL AND INSTALLATION (SEE ENGINE SHOP MANUAL)...8355
    NOZZLE HOLDER...8356
      REMOVAL AND INSTALLATION (SEE ENGINE SHOP MANUAL)...8356
    THERMOSTAT...8357
      REMOVAL AND INSTALLATION (SEE ENGINE SHOP MANUAL)...8357
    CYLINDER HEAD...8358
      REMOVAL (SEE ENGINE SHOP MANUAL)...8358
      INSTALLATION (SEE ENGINE SHOP MANUAL)...8359
    RADIATOR...8360
      REMOVAL...8360
      INSTALLATION ...8363
    ENGINE...8364
      REMOVAL ...8364
      ENGINE...8365
    TORQUE CONVERTER CHARGING PUMP...8366
      REMOVAL...8366
      INSTALLATION...8367
    TORQUE CONVERTER, TRANSMISSION...8368
      REMOVAL...8368
      INSTALLATION...8372
    TORQUE CONVERTER...8373
      DISASSEMBLY...8373
      ASSEMBLY...8375
    TRANSMISSION...8378
      DISASSEMBLY...8378
      ASSEMBLY...8388
    TRANSMISSION CLUTCH PACK...8401
      DISASSEMBLY...8401
      ASSEMBLY...8408
    TRANSMISSION CONTROL VALVE...8420
      REMOVAL...8420
      INSTALLATION...8422
      DISASSEMBLY...8423
      ASSEMBLY...8425
    TRANSMISSION ACCUMULATOR VALVE...8428
      DISASSEMBLY...8428
      ASSEMBLY...8429
    DRIVE SHAFT...8430
      DISASSEMBLY...8430
      ASSEMBLY...8433
    FRONT AXLE...8435
      REMOVAL...8435
      INSTALLATION...8437
    REAR AXLE...8438
      REMOVAL...8438
      INSTALLATION...8442
    DIFFERENTIAL...8444
      DISASSEMBLY...8444
      ASSEMBLY...8449
    AXLE HOUSING...8459
      DISASSEMBLY...8459
      ASSEMBLY...8466
    CENTER HINGE PIN...8476
      REMOVAL...8476
      INSTALLATION...8480
    STEERING VALVE...8483
      REMOVAL...8483
      INSTALLATION...8485
      DISASSEMBLY...8486
      ASSEMBLY...8490
    ORBIT-ROLL VALVE...8493
      REMOVAL...8493
      INSTALLATION...8494
      DISASSEMBLY...8495
      ASSEMBLY...8498
    STEERING CYLINDER...8503
      REMOVAL...8503
      INSTALLATION...8504
    BRAKE VALUE...8505
      REMOVAL...8505
      INSTALLATION...8506
    RIGHT BRAKE VALVE...8507
      DISASSEMBLY...8507
      ASSEMBLY...8508
    LEFT BRAKE VALVE...8509
      DISASSEMBLY...8509
      ASSEMBLY...8510
    PARKING BRAKE DISC...8511
      REMOVAL...8511
      INSTALLATION...8513
    HYDRAULIC TANK...8514
      REMOVAL...8514
      INSTALLATION...8516
    HYDRAULIC FILTER...8517
    HYDRAULIC, STEERING, SWITCH, PPC PUMP...8518
      REMOVAL...8518
      INSTALLATION...8521
    MAIN CONTROL VALVE...8522
      REMOVAL...8522
      INSTALLATION...8524
      DISASSEMBLY...8525
      ASSEMBLY...8527
    3 SPOOL VALVE...8530
      DISASSEMBLY...8530
      ASSEMBLY...8532
    PPC VALVE...8535
      REMOVAL...8535
      INSTALLATION...8537
      DISASSEMBLY...8538
      ASSEMBLY...8539
    BUCKET CYLINDER...8540
      REMOVAL...8540
      INSTALLATION...8542
    BOOM CYLINDER...8543
      REMOVAL...8543
      INSTALLATION...8544
    HYDRAULIC CYLINDER...8545
      DISASSEMBLY...8545
      ASSEMBLY...8548
    WORK EQUIPMENT...8551
      REMOVAL...8551
      INSTALLATION...8554
    COUNTERWEIGHT...8556
      REMOVAL AND INSTALLATION...8556
    FUEL TANK...8557
      REMOVAL...8557
      INSTALLATION...8559
    CAB, FLOOR FRAME...8560
      REMOVAL...8560
      INSTALLATION...8563
    CAB...8564
      REMOVAL...8564
      INSTALLATION...8565
    MAIN MONITOR...8566
      REMOVAL...8566
      INSTALLATION...8567
    MAINTENANCE MONITOR...8568
      REMOVAL AND INSTALLATION...8568
    AIR CONDITIONER UNIT...8569
      REMOVAL...8569
      INSTALLATION...8574
    AIR CONDITIONER CONDENSER...8575
      REMOVAL...8575
      INSTALLATION...8576
    DRY RECEIVER...8577
      REMOVAL AND INSTALLATION...8577
    AIR CONDITIONER CONDENSER COMPRESSOR...8578
      REMOVAL AND INSTALLATION...8578
  40 MAINTENANCE STANDARD...8579
    ENGINE MOUNT, TRANSMISSION MOUNT...8580
    TORQUE CONVERTER CHARGING PUMP...8581
    TORQUE CONVERTER...8582
    TRANSMISSION...8583
    TRANSMISSION CONTROL VALVE...8592
    FLOW CONTROL VALVE...8596
    ACCUMULATOR VALVE...8597
    DRIVE SHAFT...8598
    DIFFERENTIAL (1/2)...8599
    FINAL DRIVE...8602
    AXLE MOUNT...8604
    CENTER HINGE PIN...8605
    STEERING COLUMN...8607
    STEERING VALVE...8608
    STEERING CYLINDER MOUNT...8609
    BRAKE...8610
    BRAKE VALVE...8611
    PARKING BRAKE...8614
    MAIN CONTROL VALVE...8615
    PPC VALVE...8619
    HYDRAULIC CYLINDER...8620
    WORK EQUIPMENT LINKAGE...8621
    BUCKET...8623
    BUCKET POSITIONER AND BOOM KICK-OUT...8624
GSBM006102 - Cargadora Avance WA380-3 Manual de Taller...8626
  PORTADA...8626
  CONTENIDO...8627
  SEGURIDAD...8628
  PROLOGO...8630
     FORMA DE LEER EL MANUAL DE TALLER...8631
    INSTRUCCIONES PARA ELEVACIÓN DE PESOS...8632
    MATERIALES DE RECUBRIMIENTO...8633
    TORSIÓN ESTÁNDAR...8634
    TABLAS DE CONVERSIÓN...8637
  01 GENERAL...8643
    DIBUJO DE ENSAMBLAJE GENERAL...8644
    ESPECIFICACIONES...8645
    TABLA DE PESO...8648
    SELECCION APROPIADA DE COMBUSTIBLE, REFRIGERANTE Y LUBRICANTES...8649
  10 ESTRUCTURA Y FUNCIONAMIENTO...8651
    TREN DE POTENCIA...8653
    SISTEMA DEL TREN DE POTENCIA...8654
    CONVERTIDOR DE TORSIÓN, TUBERÍAS DE LA TRANSMISIÓN...8656
    DIAGRAMA DEL SISTEMA HIDRÁULICO DE LA TRANSMISIÓN...8658
    DIAGRAMA DEL CIRCUITO HIDRÁULICO DE LA TRANSMISIÓN...8659
    CONVERTIDOR DE TORSIÓN...8660
    FILTRO DE ACEITE DEL CONVERTIDOR...8662
    TRANSMISIÓN...8664
    VÁLVULA DE CONTROL DE LA TRANSMISION...8674
    EJE TRANSMISOR...8696
    DIFERENCIAL...8699
    MANDO FINAL...8703
    MONTAJE DEL EJE, PASADOR CENTRAL DE ARTICULACIÓN...8704
    TUBERÍAS DE DIRECCIÓN...8706
    COLUMNA DE LA DIRECCION...8707
    VÁLVULA DE LA DIRECCIÓN...8708
    CARRETE DE DIRECCIÓN EN OPERACIÓN...8710
    OPERACIÓN DE LA VÁLVULA DE DIRECCIÓN...8715
    VÁLVULA DE ALIVIO DE LA DIRECCIÓN...8718
    VÁLVULA ORBIT-ROLL...8722
    VÁLVULA DE PARADA...8726
    BOMBA DE EMERGENCIA PARA LA DIRECCIÓN...8727
    VÁLVULA DESVIADORA...8728
    TUBERÍAS PARA LOS FRENOS...8732
    DIAGRAMA DEL CIRCUITO HIDRÁULICO DE LOS FRENOS...8733
    VÁLVULA DEL FRENO...8734
    VÁLVULA DE CARGA DEL ACUMULADOR...8739
    ACUMULADOR (PARA EL FRENO)...8743
    FRENO...8745
    CONTROL DEL FRENO DE ESTACIONAMIENTO...8747
    FRENO DE ESTACIONAMIENTO...8748
    VALVULA SOLENOIDE DEL FRENO DE ESTACIONAMIENTO...8749
    TUBERÍAS HIDRÁULICAS...8753
    DIAGRAMA DEL SISTEMA HIDRÁULICO DEL EQUIPO DE TRABAJO...8754
    DIAGRAMA DEL CIRCUITO HIDRÁULICO DEL EQUIPO DE TRABAJO...8755
    VARILLAJE DE LAS PALANCAS DEL EQUIPO DE TRABAJO...8757
    TANQUE HIDRÁULICO...8758
    VÁLVULA DE DESVÍO DEL FILTRO DE ACEITE...8759
    VÁLVULA PPC...8760
    VÁLVULA DE CONTROL PRINCIPAL...8768
    VARILLAJE DEL EQUIPO DE TRABAJO...8784
    CUCHARÓN...8786
    CABINA...8793
    ACONDICIONADOR DE AIRE...8794
    DIAGRAMA DEL CIRCUITO ELECTRICO...8804
    SISTEMA MONITOR DE LA MAQUINA...8812
      MONITOR PRINCIPAL...8813
      MONITOR DE MANTENIMIENTO...8818
    SISTEMA DE CONTROL DEL EQUIPO DE TRABAJO...8821
      CONTROLADOR...8826
      POTENCIÓMETRO...8827
      E.C.S.S...8828
      SENSORES...8832
      CIRCUITO DE ARRANQUE DEL MOTOR...8836
      CIRCUITO DE PARADA DEL MOTOR...8837
      CIRCUITO DE PRECALENTAMIENTO...8838
      DISYUNTOR DEL DESCONECTOR...8842
    DIAGRAMA DEL CIRCUITO ELÉCTRICO DEL DESCONECTOR...8843
    INTERRUPTOR DE CORTE DE LA TRANSMISION...8848
    CONTROL ELECTRICO DEL FRENO DE ESTACIONAMIENTO...8851
  20 PRUEBAS Y REGULACIONES...8863
    TABLA ESTANDARD DE VALORES PARA EL MOTOR...8864
    TABLA ESTANDARD DE VALORES PARA EL CHASIS...8865
    TABLA ESTANDARD DE VALORES PARA EL SISTEMA ELECTRICO...8869
    LISTADO DE HERRAMIENTAS PARA PRUEBAS Y REGULACIONES...8873
    AJUSTE DE LA HOLGURA DE LAS VALVULAS...8874
    MEDICIÓN DE LA PRESIÓN DE COMPRESION...8875
    MEDICIÓN DE FUGAS DE COMPRESIÓN...8876
    COMPROBACIÓN Y AJUSTE DE LA SINCRONIZACION DE LA INYECCION...8877
    MEDICIÓN DEL COLOR DEL HUMO DEL ESCAPE...8879
    MEDICIÓN DE LA PRESIÓN DEL AIRE DE ADMISION (PRESION REFORZADORA)...8880
    MEDICIÓN DE LA TEMPERATURA DE LOS GASES DE ESCAPE...8881
    MEDICIÓN DE LA PRESIÓN DE ACEITE DEL MOTOR...8882
    MEDICIÓN DE LA VELOCIDAD DEL MOTOR...8883
    PRUEBAS Y AJUSTES DE LA TENSIÓN DE LA CORREA DEL VENTILADOR...8884
    MÉTODO PARA AJUSTAR EL CABLE DEL MOTOR DE PARADA DEL MOTOR DE COMBUSTION...8885
    MEDICIÓN DEL PEDAL DEL ACELERADOR...8887
    MEDICIÓN DE LA FUERZA DE OPERACION, RECORRIDO DE LA PALANCA DE VELOCIDAD...8889
    MEDICIÓN DE LA PRESIONA DE ACEITE DEL CONVERTIDOR, TRANSMISION Y FRENO DE ESTACIONAMIENTO...8892
    MÉTODO DE OPERACIÓN DEL CARRETE MANUAL DE EMERGENCIA...8894
    MEDICIÓN DE LA HOLGURA ENTRE EL NEUMATICO Y LA RUEDA...8896
    PRUEBA Y AJUSTE DEL VOLANTE DE LA DIRECCION...8897
    MEDICIÓN DE LA PRESIÓN DEL ACEITE DE LA DIRECCION...8901
    MEDICIÓN DE LA FUERZA DE OPERACION, RECORRIDO DEL PEDAL DEL FRENO...8903
    MEDICIÓN DEL COMPORTAMIENTO DE LOS FRENOS...8904
    COMPROBACIÓN DE LA PRESIÓN DEL ACEITE DE LOS FRENOS...8905
    COMPROBACIÓN DEL DESGASTE DE LOS DISCOS DEL FRENO...8906
    PURGA DEL AIRE EN EL SISTEMA DE FRENOS...8907
    MEDICIÓN DEL COMPORTAMIENTO DEL FRENO DE ESTACIONAMIENTO...8908
    MÉTODO PARA SOLTAR MANUALMENTE EL FRENO DE ESTACIONAMIENTO...8909
    COMPROBACIÓN DEL DESGASTE DEL DISCO DEL FRENO DE ESTACIONAMIENTO...8910
    MEDICIÓN DE LA PALANCA DE CONTROL DEL EQUIPO DE TRABAJO...8911
    MEDICIÓN DE LA PRESIÓN HIDRÁULICA DEL EQUIPO DE TRABAJO...8913
    MEDICIÓN DE LA PRESIÓN EN LA VALVULA PPC...8915
    MEDICIÓN DEL EQUIPO DE TRABAJO...8917
    COMPROBACIÓN Y AJUSTE DEL POSICIONADOR DEL CUCHARON...8919
    PRUEBAS Y AJUSTES DEL DESCONECTOR DEL CUCHARON...8920
    AJUSTE DEL MONITOR PRINCIPAL (MODULO DEL VELOCIMETRO)...8922
    AJUSTE DE LOS POTENCIÓMETROS DE LOS ANGULOS DEL BRAZO Y DEL CUCHARON...8923
    LOCALIZACIÓN DE FALLAS Y AVERÍAS...8924
      SECUENCIA DE EVENTOS EN LA LOCALIZACIÓN DE FALLAS Y AVERIAS...8926
      PRECAUCIONES AL REALIZAR EL MANTENIMIENTO...8927
      MANIPULACIÓN DE CONECTORES...8934
      COMPROBACIONES ANTES DE LOCALIZAR FALLAS Y AVERÍAS...8935
      MÉTODO PARA EL USO DE LAS TABLAS DE LOCALIZACIÓN DE FALLAS Y AVERIAS...8937
      TIPOS DE CONECTORES Y UBICACIONES DE MONTAJE...8945
      DIAGRAMA (1/3) DEL UBICACIÓN DE LAS CLAVIJAS DE CONEXIÓN...8946
      TABLA DE CONEXIONES SEGÚN LOS NUMEROS DE LAS ESPIGAS DE LOS CONECTORES...8951
      LOCALIZACIÓN DE FALLAS Y AVERÍAS EN EL SISTEMA DEL MOTOR (MODO S)...8958
      LOCALIZACIÓN DE FALLAS Y AVERÍAS EN EL SISTEMA MONITOR PRINCIPAL (MODO M)...8977
      LOCALIZACIÓN DE FALLAS Y A. MONITOR MANT. (MODO K)...9010
      LOCALIZACIÓN DE FALLAS Y AVERÍAS EN EL SIST. ELECTRICO (MODO E)...9030
      LOCALIZACIÓN DE FALLAS Y AVERIAS DEL SISTEMA HIDRAULICO Y MECANICO (RELACIONADAS CON EL CHASIS) (MODO T)...9072
        TREN DE POTENCIA...9073
        SISTEMA DE LA DIRECCIÓN...9080
        SISTEMA DE FRENOS...9083
        EQUIPO DE TRABAJO...9086
      LOCALIZACIÓN DE FALLAS Y AVERÍAS DEL ECSS (MODO D)...9095
      LOCALIZACION DE FALLAS Y AVERIAS DEL SISTEMA CONTROLADOR DEL EQUIPO DE TRABAJO (MODO W)...9108
SEBM006104 - Wheel Loader WA380-3 Loader avance Shop Manual...9141
  CONTENTS...9142
  01 GENERAL...9164
    GENERAL ASSEMBLY DRAWING ...9165
    SPECIFICATIONS ...9167
    WEIGHT TABLE ...9170
    LIST OF LUBRICANT AND WATER ...9172
  10 STRUCTURE AND FUNCTION ...9174
    POWER TRAIN ...9175
    POWER TRAIN SYSTEM ...9176
    TORQUE CONVERTER, TRANSMISSION PIPING ...9178
    TRANSMISSION HYDRAULIC SYSTEM DIAGRAM ...9179
    TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM ...9180
    TORQUE CONVERTER ...9181
    TORQUE CONVERTER OIL FILTER ...9183
    TRANSMISSION ...9184
    TRANSMISSION CONTROL VALVE ...9194
    DRIVE SHAFT ...9216
    AXLE...9217
    DIFFERENTIAL ...9219
    FINAL DRIVE ...9223
    AXLE MOUNT, CENTER HINGE PIN ...9224
    STEERING PIPING ...9226
    STEERING COLUMN ...9227
    STEERING VALVE ...9228
    ORBIT-ROLL VALVE ...9242
    STOP VALVE ...9246
    EMERGENCY STEERING PUMP ...9247
    DIVERTER VALVE ...9248
    BREAK PIPING...9251
    BRAKE HYDRAULIC CIRCUIT DIAGRAM ...9252
    BRAKE VALVE ...9253
    ACCUMULATOR CHARGE VALVE...9258
    ACCUMULATOR (FOR BRAKE) ...9264
    BRAKE...9266
    PARKING BRAKE CONTROL ...9268
    PARKING BRAKE ...9269
    PARKING BRAKE SOLENOID VALVE ...9270
    PARKING BRAKE VALVE ...9271
    PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE ...9272
    HYDRAULIC PIPING...9273
    WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM...9274
    WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...9275
    WORK EQUIPMENT LEVER LINKAGE ...9279
    HYDRAULIC TANK ...9280
    PPC VALVE ...9282
    PPC RELIEF VALVE...9287
    ACCUMULATOR  (FOR PPC VALVE) ...9288
    MAIN CONTROL VALVE ...9289
    WORK EQUIPMENT LINKAGE ...9304
    BUCKET ...9306
    BUCKET  POSITIONER  AND BOOM KICK-OUT ...9307
    CAB...9313
    ROPS CAB ...9315
    AIR CONDITIONER ...9316
    ELECTRIC CIRCUIT DIAGRAM ...9327
    MACHINE MONITOR SYSTEM ...9328
    MAIN MONITOR ...9329
    MAINTENANCE  MONITOR ...9334
    WORK EQUIPMENT CONTROL SYSTEM ...9337
    E.C.S.S. (Electronically Controlled  Suspension  System) ...9344
    SENSORS ...9348
    ENGINE STARTING CIRCUIT ...9352
    ENGINE STOP CIRCUIT ...9353
    PREHEATING CIRCUIT...9354
    ELECTRIC TRANSMISSION  CONTROL ...9355
    KICK-DOWN SWITCH ...9358
    KICK-DOWN ELECTRIC CIRCUIT DIAGRAM ...9359
    TRANSMISSION  CUT-OFF SWITCH ...9364
    TRANSMISSION  CUT-OFF FUNCTION ...9365
    ELECTRIC PARKING BRAKE CONTROL ...9367
  20 TESTING AND ADJUSTING ...9379
    STANDARD VALUE TABLE FOR ENGINE ...9380
    STANDARD VALUE TABLE FOR CHASSIS ...9381
    STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM ...9385
    TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING ...9389
    ADJUSTING VALVE CLEARANCE ...9390
    MEASURING COMPRESSION PRESSURE ...9391
    MEASURING  BLOW-BY  PRESSURE ...9392
    TESTING AND ADJUSTING FUEL INJECTION TIMING ...9393
    MEASURING EXHAUST COLOR ...9395
    MEASURING INTAKE AIR  PRESSURE (BOOST PRESSURE) ...9396
    MEASURING EXHAUST GAS TEMPERATURE ...9397
    MEASURING ENGINE OIL  PRESSURE ...9398
    MEASURING ENGINE SPEED ...9399
    TESTING AND ADJUSTING FAN BELT TENSION ...9400
    METHOD FOR ADJUSTING  ENGINE STOP MOTOR CABLE ...9401
    MEASURING ACCELERATOR  PEDAL ...9403
    MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER ...9405
    MEASURING STALL SPEED ...9406
    MEASURING TORQUE CONVERTER, TRANSMISSION, PARKING BRAKE OIL PRESSURE ...9408
    METHOD OF OPERATING EMERGENCY MANUALSPOOL ...9410
    MEASURING CLEARANCE BETWEEN TIRE AND WHEEL ...9412
    TESTING AND ADJUSTING STEERING WHEEL ...9413
    TESTING AND ADJUSTING STEERING CONTROL ...9416
    MEASURING STEERING OIL PRESSURE ...9417
    MEASURING OPERATING  FORCE, TRAVEL OF BRAKE PEDAL ...9419
    MEASURING BRAKE PERFORMANCE ...9420
    TESTING BRAKE OIL PRESSURE ...9421
    TESTING FOR BRAKE DISC WEAR ...9422
    BLEEDING AIR FROM BRAKE  SYSTEM ...9423
    MEASURING  PARKING BRAKE PERFORMANCE ...9424
    MANUAL RELEASE METHOD FOR PARKING BRAKE ...9425
    TESTING WEAR OF PARKING BRAKE DISC ...9426
    MEASURING WORK EQUIPMENT CONTROL LEVER ...9427
    MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE ...9429
    MEASURING PPC VALVE PRESSURE ...9431
    MEASURING WORK  EQUIPMENT ...9433
    TESTING AND ADJUSTING  BUCKET  POSITIONER ...9435
    TESTING AND ADJUSTING  BOOM  KICK-OUT ...9436
    ADJUSTING MAIN MONITOR  (SPEEDOMETER MODULE) ...9438
    ADJUSTING BOOM, BUCKET  ANGLE  POTENTIOMETER ...9439
    TROUBLESHOOTING...9440
      POINTS TO REMEMBER WHEN TROUBLESHOOTING ...9441
      SEQUENCE OF EVENTS IN TROUBLESHOOTING ...9442
      PRECAUTIONS WHEN CARRYING OUT MAINTENANCE ...9443
      HANDLING CONNECTORS ...9450
      CHECKS BEFORE TROUBLESHOOTING ...9451
      METHOD OF USING TROUBLESHOOTING CHARTS ...9452
      CONNECTOR TYPES AND MOUNTING LOCATIONS...9460
      CONNECTOR PIN ARRANGEMENT DIAGRAM...9461
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ...9466
      TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) ...9473
        S-1 Starting performance is poor  (Starting always takes time) ...9474
        S-2 Engine does not start ...9475
          (1) Engine does not turn...9475
          (2) Engine turns but no exhaust gas comes out (Fuel is not being injected)...9476
          (3) Exhaust gas comes out but engine does not start (Fuel is being injected)...9477
        S-3 Engine does not pick up smoothly (Follow-up is poor) ...9478
        S-4 Engine stops during operations ...9479
        S-5 Engine does not rotate smoothly (hunting) ...9480
        S-6 Engine lacks output (no power) ...9481
        S-7 Exhaust gas is black (incomplete combustion) ...9482
        S-8 Oil consumption is excessive (or exhaust gas is blue) ...9483
        S-9 Oil becomes contaminated quickly ...9484
        S-10 Fuel consumption is excessive ...9485
        S-11 Oil is in cooling water, or water spurts back, or water level goes down...9486
        S-12 Oil pressure lamp lights up (drop in oil pressure) ...9487
        S-13 Oil level rises ...9488
        S-14 Water temperature becomes too high  (overheating) ...9489
        S-15 Abnormal noise is made...9490
        S-16 Vibration is excessive...9491
      TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) ...9492
        TROUBLE DATA DISPLAY ...9494
        M-1 Main monitor does not work...9496
        M-2 When starting switch is turned ON and engine is started  immediately, all lamps stay lighted up ...9497
        M-3 Speedometer display does not work properly ...9498
        M-4 Abnormality in shift indicator ...9499
          (a) Stays at N even when directional lever is at F...9499
          (b) Stays at N even when directional lever is at R...9499
          (c) Does not display N even when directional lever is at N and displays R when directional lever is at F...9499
          (d) Does not display N even when directional lever is at N and displays F when directional lever is at R...9500
          (e) Does not display lst, 4th...9500
          (f) Does not display 3rd, 4th...9500
          (g) Does not display 2nd, 3rd...9501
          (h) Does not display 1st, 2nd...9501
        M-5 High beam does not light up ...9502
        M-6 Turn signal display does not light up ...9503
          (a) L.H. turn signal does not light up...9503
          (b) R.H. turn signal does not light up...9503
        M-7 Abnormality in parking display ...9504
          (a) Parking lamp does not light up...9504
          (b) Parking lamp stays lighted up...9504
        M-8 Abnormality in preheating system (QGS) ...9505
          (a) Does not carry out preheating...9505
          (b) Always carries out preheating for 1 minute...9506
          (c) Preheating stays on...9506
          (d) Preheating time becomes shorter, or there is variation...9507
        M-9 Night lighting does not light up ...9508
        M-10 Abnormality in front working lamp ...9509
          (a) Neither monitor display nor front working lamp light up...9509
          (b) Working lamp lights up but monitor display does not light up...9509
          (c) Monitor lights up but working lamp does not light up...9509
        M-11 Abnormality in rear working lamp...9510
          (a) Neither monitor display nor rear working lamp light up...9510
          (b) Working lamp lights up but monitor display does not light up...9510
          (c) Monitor lights up but working lamp does not light up...9510
        M-12 Abnormality in transmission cut-off...9512
          (a) When monitor switch is pressed, cut-off function is not switched and display is not given...9512
          (b) Monitor display goes out but cut-off function stays on...9512
          (c) Monitor display lights up but cut-off function is not actuated...9513
        M-13 Abnormality in parking brake dragging warning...9514
          (a) When parking brake is applied, buzzer sounds (intermittently) even when directional lever is at N, and caution lamp flashes...9514
          (b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even when directional lever is at po...9514
        M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated...9515
          (a) Actuated continuously...9515
          (b) Not actuated...9515
        M-15 Abnormality in buzzer...9516
          (a) Buzzer does not sound when starting switch is turned ON (during self-check)...9516
          (b) Buzzer always sounds...9516
        M-16 Condition of monitor switches is not stored in memory...9517
        M-17 Abnormality in failure display mode...9518
          (a) Does not enter failure display mode...9518
          (b) Time for time elapsed since failure on failure display mode does not advance...9518
        M-18 Abnormality in emergency steering normal display...9519
          (a) Emergency steering normal display does not light up...9519
          (b) Emergency steering normal display stays lighted up...9519
        M-19 Abnormality in emergency steering actuation display...9520
          (a) Emergency steering actuation display does not light up...9520
          (b) Emergency steering actuation display stays lighted up...9520
        M-20 Abnormality in auto-greasing system...9521
          (a) Forced greasing cannot be carried out...9521
          (b) Monitor display flashes rapidly (2 times/sec)...9521
          (c) When no more grease remains, monitor display flashes rapidly (2 times/sec)...9521
          (d) Monitor display flashes slowly (1 time/sec)...9522
          (e) Monitor display goes out...9522
        M-21 Abnormality in ECSS system...9523
          (a) Display does not change when switch is pressed...9523
          (b) Monitor display lights up but ECSS function does not work...9523
        M-22 Buzzer does not sound when auto-leveling switch is actuated...9523
        M-23 Failure code is not sent to main monitor (abnormality in network)...9524
      TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE) ...9525
        K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 sec., maintenance monitor does not...9526
          (a) All lamps on maintenance monitor do not light up for 3 seconds...9526
          (b) Some lamps do not light up...9527
        K-2 When starting switch is turned ON, all lamps on maintenance  monitor light up but do not go out ...9527
        K-3 When engine is started immediately after starting switch is turned  ON (within 3 seconds), all lamps on maintenance monitor do not  go out ...9528
        K-4 When starting switch is turned ON (engine stopped), CHECK items  flash ...9529
          (a) Engine oil level display flashes...9529
          (b) Engine water level display flashes...9530
        K-5 When starting switch is turned ON (engine started), CAUTION  items flash ...9531
          (a) Engine oil pressure display flashes...9531
          (b) Battery charge level display flashes...9532
          (c) Brake oil pressure display flashes...9533
          (d) Air cleaner display flashes...9534
        K-6 CAUTION items are flashing but alarm buzzer does not sound ...9535
        K-7 There is no abnormality in monitor display but alarm buzzer  sounds ...9536
        K-8 CAUTION items are flashing but warning lamp (CHECK lamp,  CAUTION lamp) does not light up ...9537
          (a) CHECK lamp...9537
          (b) CAUTION lamp...9537
        K-9 There is no abnormality in maintenance monitor display but  warning lamp (CHECK lamp, CAUTION lamp) lights up ...9538
          (a) CHECK lamp...9538
          (b) CAUTION lamp...9538
        K-10 Night lighting does not light up when lamp switch is turned ON  (only lighting of maintenance monitor does not light up) ...9539
        K-11 Night lighting lights up even when lamp switch is OFF, night  lighting stays lighted up ...9540
        K-12 Service meter does not work ...9541
        K-13 Service meter is running even when engine is stopped...9541
        K-14 Abnormality in gauge items ...9542
          (a) Abnormality in fuel gauge...9542
          (b) Abnormality in engine water temperature gauge...9543
          (c) Abnormality in torque converter oil temperature gauge...9544
      TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) ...9545
        E-1 Engine does not start ...9546
          (a) Starting motor does not turn...9546
          (b) Starting motor turns...9550
        E-2 Engine does not stop ...9552
        E-3 Engine stops when machine is traveling ...9552
        E-4 Parking brake does not work ...9553
          (a) Parking brake has no effect when parking brake switch is turned ON (parking)...9553
          (b) Parking brake has no effect when brake pressure drops (Does not work as emergency brake)...9553
        E-5 Parking brake is applied when machine is traveling ...9554
        E-6 Parking brake is released when starting switch is turned ON ...9556
        E-7 Transmission does  when parking brake is applied  (but parking brake works normally) ...9556
        E-8 Transmission does not work normally ...9557
          (a) Problem in common circuit for transmission (always stays in 2nd)...9559
          (b) Problem in H-L circuit...9559
          (c) Problem in speed circuit...9560
          (d) Problem in 4th circuit (does not enter 4th)...9560
          (e) Contact in H-L circuit...9561
          (f) Contact in speed circuit...9563
          (g) Contact in 4th circuit (always stays in 4th)...9565
          (h) Problem in FORWARD circuit (REVERSE is normal)...9566
          (i) Problem in REVERSE circuit (FORWARD is normal)...9568
          (j) Problem in common circuit for FORWARD and REVERSE (does not travel forward, parking brake is normal)...9570
          (k) Contact in FORWARD circuit...9572
          (I) Contact in REVERSE circuit...9574
          (m) Problem in common circuit for FORWARD and REVERSE...9576
        E-9 Kick-down switch does not work  (the regular F1 to F4 shifts normally)...9577
        E-10  Kick-down works only when kick-down switch is ON (Kick-down  switch relay does not hold in position (self-holding function) ...9579
        E-11 Kick-down operation cannot be canceled ...9579
          (a) Not canceled even when directional lever is moved from F to N or R...9579
          (b) Not canceled even when speed lever is moved from 2nd to other position (becomes 4th)...9580
        E-12 Kick-down switch is actuated by mistake when traveling in 2nd ...9582
      TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE) ...9583
        POWER TRAIN ...9584
          T-1 Machine does not start ...9584
          T-2 Travel speed is slow, thrusting power is weak, lacks power on  slopes ...9586
          T-3 Excessive shock when starting machine or shifting gear ...9588
          T-4 Excessive time lag when starting machine or shifting gear ...9589
          T-5 Torque converter oil temperature is high ...9590
        STEERING SYSTEM ...9591
          T-6 Steering does not turn ...9591
          T-7 Steering wheel is heavy ...9592
          T-8 Steering wheel wobbles or  there is excessive shock ...9593
          T-9 Machine steers to one side  when traveling ...9593
          T-10 Turning radius to left and  right is different ...9593
        BRAKE SYSTEM ...9594
          T-11 Brakes do not work or braking effect is poor ...9594
          T-12 Brakes are not released or brakes drag ...9595
          T-13 Parking brake is not released or brake drags ...9596
        WORK EQUIPMENT ...9597
          T-14 Boom does not rise ...9597
          T-15 Boom movement is slow or boom lacks lifting power ...9598
          T-16 When boom is raised, it moves slowly at a certain height ...9599
          T-17 Bucket cannot be pushed with cylinder (bucket floats) ...9599
          T-18 Excessive hydraulic drift of boom ...9599
          T-19 Boom shakes during operation ...9599
          T-20 Boom drops momentarily when control lever is operated from  HOLD to RAISE ...9600
          T-21 Bucket does not tilt back ...9601
          T-22 Bucket movement is slow or tilt-back lacks power ...9602
          T-23 Bucket movement becomes slow during tilt-back operation ...9603
          T-24 Bucket cannot be pushed with bucket cylinder ...9603
          T-25 Excessive hydraulic drift of bucket ...9603
          T-26 Bucket shakes during loading operation  (Main control valve at HOLD) ...9604
          T-27 Bucket dumps momentarily when control lever is operated from  HOLD to TILT ...9604
          T-28 Boom, bucket control levers are heavy or do not move smoothly ...9605
      TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE) ...9606
        JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM ...9607
        D-1 ECSS does not work ...9608
          (a) Error code [d0] is displayed...9609
          (b) Error code [d1] is displayed...9609
          (c) Error code [d2] is displayed...9610
          (d) Error code [d3] is displayed...9610
          (e) Error code [d4] is displayed...9611
          (f) No abnormality display is given...9611
        D-2 ECSS cannot be canceled ...9615
        D-3 Output is turned ON (travel speed does not become 5 km/h)  (deviates around 5 km/h) ...9616
        D-4 Output is turned ON when transmission...9616
        D-5 Output is turned ON when transmission is in 4th ...9617
        D-6 Controller LED code is not displayed ...9618
        D-7 ECSS is abnormal but main monitor does not give abnormality  display ...9618
      TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (W MODE) ...9619
        OUTLINE ...9621
        1. Function...9621
        2. When carrying out troubleshooting...9621
        3. Failure code table...9621
        4. Table of troubleshooting modes and causes...9622
        W-1 Failure code [40] Abnormality in bucket dump solenoid system ...9624
        W-2 Failure code [41] Short circuit in power source when bucket  DUMP, TILT solenoids are OFF ...9625
        W-3 Failure code [42] Abnormality in bucket tilt solenoid system ...9626
        W-4 Failure code [43] Abnormality in damping solenoid system ...9627
        W-5 Failure code [44]Short circuit in power source at hot end of  damping solenoid ...9628
        W-6 Failure code [45]Short circuit in power source at return end of  damping solenoid ...9628
        W-7 Failure code [48] Abnormality in bucket lever kick-out relay  system ...9629
        W-8 Failure code [49] Abnormality in boom lever kick-out relay system ...9631
        W-9 Failure code [50] Abnormality in auto-leveler relay system ...9632
        W-10 Failure code [51] Disconnection in boom RAISE, LOWER  detection pressure switch ...9633
        W-11 Failure code [52] Abnormality in boom angle potentiometer  system ...9634
        W-12 Failure code [53] Abnormality in bucket angle potentiometer  system ...9634
        W-13 Failure code [54] Abnormality in model selection wiring harness ...9636
        W-14 Sensor cannot be adjusted ...9637
        W-15 Does not carry out auto-leveling ...9638
          (a) Auto-leveler switch system...9638
          (b) Auto-leveler LED system...9638
          (c) Bucket lever neutral switch system...9639
          (d) Engine speed signal system...9640
        W-16 Auto-leveler cannot be set ...9641
          (a) Auto-leveler set switch system...9641
          (b) Auto-leveler set LED system...9641
        W-17 Remote positioner RAISE, LOWER LEDs do not light up ...9642
          (a) Remote positioner switch system...9642
          (b) Remote positioner LED system...9642
        W-18 Remote positioner set LEDs do not flash ...9643
          (a) Remote positioner switch system...9643
          (b) Remote positioner LED system...9643
        W-19 Bucket does not tilt immediately at boom FLOAT detent when  remote positioner is at RAISE and auto mode is ON ...9644
        W-20 Buzzer for switch operation does not sound ...9645
        W-21 Bucket correction, boom stop response are slow ...9646
        W-22 Bucket (lever) control ...9647
          (a) Bucket kick-out does not work even when bucket is at maximum tilt...9647
          (b) Lever is not held by detent...9648
        W-23 Failure code is not displayed on main monitor ...9650
        W-24 Maintenance monitor check ...9651
  30 DISASSEMBLY AND ASSEMBLY...9652
    METHOD OF USING MANUAL ...9654
    PRECAUTIONS WHEN CARRYING OUT OPERATION ...9655
    SPECIAL TOOL LIST ...9657
    STARTING MOTOR ...9659
      REMOVAL AND INSTALLATION...9659
    ALTERNATOR ...9660
      REMOVAL AND INSTALLATION...9660
    ENGINE OIL COOLER ...9661
      REMOVAL AND INSTALLATION...9661
    FUEL INJECTION PUMP ...9662
      REMOVAL...9662
      INSTALLATION...9663
    WATER PUMP ...9664
      REMOVAL AND INSTALLATION...9664
    TURBOCHARGER...9666
      REMOVAL AND INSTALLATION...9666
    NOZZLE  HOLDER ...9667
      REMOVAL AND INSTALLATION...9667
    THERMOSTAT ...9668
      REMOVAL AND INSTALLATION...9668
    CYLINDER HEAD...9669
      REMOVAL...9669
      INSTALLATION...9674
    RADIATOR...9676
      REMOVAL...9676
      INSTALLATION...9679
    ENGINE...9680
      REMOVAL...9680
      INSTALLATION...9685
    TORQUE CONVERTER CHARGING PUMP...9686
      REMOVAL...9686
      INSTALLATION...9687
    TORQUE CONVERTER, TRANSMISSION...9688
      REMOVAL...9688
      INSTALLATION...9692
    TORQUE CONVERTER...9693
      DISASSEMBLY...9693
      ASSEMBLY...9695
    TRANSMISSION...9698
      DISASSEMBLY...9698
      ASSEMBLY...9708
    TRANSMISSION CLUTCH PACK...9722
      DISASSEMBLY...9722
      ASSEMBLY...9728
    TRANSMISSION CONTROL VALVE...9740
      REMOVAL...9740
      INSTALLATION...9742
      DISASSEMBLY...9743
      ASSEMBLY...9745
    TRANSMISSION ACCUMULATOR VALVE...9748
      DISASSEMBLY...9748
      ASSEMBLY...9749
    TRANSMISSION MODULATING VALVE...9750
      DISASSEMBLY...9750
      ASSEMBLY...9751
    DRIVE SHAFT...9752
      DISASSEMBLY...9752
      ASSEMBLY...9755
    FRONT AXLE...9757
      REMOVAL...9757
      INSTALLATION...9759
    REAR AXLE...9760
      REMOVAL...9760
      INSTALLATION...9764
    DIFFERENTIAL...9766
      DISASSEMBLY...9766
      ASSEMBLY...9771
    AXLE HOUSING...9781
      DISASSEMBLY...9781
      ASSEMBLY...9788
    CENTER HINGE PIN...9798
      REMOVAL...9798
      INSTALLATION...9802
    STEERING VALVE...9805
      REMOVAL...9805
      INSTALLATION...9807
      DISASSEMBLY...9808
      ASSEMBLY...9812
    ORBIT-ROLL VALVE...9815
      REMOVAL...9815
      INSTALLATION...9816
      DISASSEMBLY...9817
      ASSEMBLY...9820
    STEERING CYLINDER...9825
      REMOVAL...9825
      INSTALLATION...9826
    BRAKE VALVE...9827
      REMOVAL...9827
      INSTALLATION ...9828
    RIGHT  BRAKE  VALVE (TANDEM) ...9829
      DISASSEMBLY...9829
      ASSEMBLY ...9830
    LEFT BRAKE  VALVE (SINGLE) ...9831
      DISASSEMBLY...9831
      ASSEMBLY ...9832
    PARKING BRAKE DISC ...9833
      REMOVAL...9833
      INSTALLATION...9835
    HYDRAULIC TANK...9836
      REMOVAL...9836
      INSTALLATION...9838
    HYDRAULIC FILTER...9839
      REMOVAL AND INSTALLATION...9839
    HYDRAULIC,  STEERING,  SWITCH,  PPC  PUMP...9840
      REMOVAL...9840
      INSTALLATION...9843
    MAIN CONTROL VALVE...9844
      REMOVAL...9844
      INSTALLATION ...9846
      DISASSEMBLY...9847
      ASSEMBLY...9849
    PPC VALVE ...9852
      REMOVAL...9852
      INSTALLATION...9854
      DISASSEMBLY...9855
      ASSEMBLY ...9856
    BUCKET CYLINDER...9857
      REMOVAL...9857
      INSTALLATION...9859
    BOOM CYLINDER ...9860
      REMOVAL...9860
      INSTALLATION...9861
    HYDRAULIC CYLINDER ...9862
      DISASSEMBLY...9862
      ASSEMBLY...9865
    WORK  EQUIPMENT...9868
      REMOVAL...9868
      INSTALLATION ...9871
    COUNTERWEIGHT ...9873
      REMOVAL AND INSTALLATION...9873
    FUEL TANK ...9874
      REMOVAL...9874
      INSTALLATION ...9876
    CAB, FLOOR  FRAME...9877
      REMOVAL...9877
      INSTALLATION...9880
    CAB...9881
      REMOVAL...9881
      INSTALLATION...9882
    MAIN MONITOR...9883
      REMOVAL...9883
      INSTALLATION...9884
    MAINTENANCE MONITOR...9885
      REMOVAL AND INSTALLATION...9885
    AIR CONDITIONER UNIT ...9886
      REMOVAL...9886
      INSTALLATION ...9891
    AIR CONDITIONER CONDENSER...9892
      REMOVAL...9892
      INSTALLATION...9893
    DRY RECEIVER...9894
      REMOVAL AND INSTALLATION...9894
    AIR CONDITIONER CONDENSER COMPRESSOR ...9895
      REMOVAL AND INSTALLATION...9895
  40 MAINTENANCE STANDARD ...9896
    ENGINE MOUNT, TRANSMISSION MOUNT ...9897
    TORQUE CONVERTER CHARGING PUMP ...9898
    TORQUE CONVERTER ...9899
    TRANSMISSION...9900
    TRANSMISSION CONTROL VALVE ...9908
    MODULATION VALVE ASSEMBLY ...9912
    ACCUMULATOR  VALVE ...9913
    DRIVE SHAFT ...9914
    DIFFERENTIAL ...9915
    FINAL DRIVE ...9918
    AXLE MOUNT ...9920
    CENTER HINGE PIN ...9921
    STEERING COLUMN ...9923
    STEERING VALVE ...9924
    STEERING CYLINDER MOUNT ...9925
    BRAKE ...9926
    BRAKE VALVE ...9927
    PARKING BRAKE ...9930
    HYDRAULIC PUMP...9931
    MAIN CONTROL VALVE ...9932
    PPC VALVE ...9936
    HYDRAULIC CYLINDER ...9937
    WORK  EQUIPMENT LINKAGE ...9938
    BUCKET ...9940
    BUCKET POSITIONER AND BOOM KICK-OUT ...9941
SEBM024711 - Wheel Loader WA380-5 Shop Manual...9943
  COVER...9943
  CONTENTS...9944
  01 GENERAL...9971
    GENERAL ASSEMBLY DRAWING...9972
    SPECIFICATIONS...9973
    WEIGHT TABLE...9977
    LIST OF LUBRICANT AND COOLANT...9979
  10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD...9980
    COOLING SYSTEM...9981
    ENGINE MOUNT, TRANSMISSION MOUNT...9982
    POWER TRAIN...9983
    POWER TRAIN SYSTEM DIAGRAM...9984
    DRIVE SHAFT (PROPELLER SHAFT)...9987
    TORQUE CONVERTER, TRANSMISSION PIPING...9988
    TORQUE CONVERTER...9989
    TRANSMISSION...9997
    TRANSMISSION CONTROL VALVE...10012
    AXLE...10027
    DIFFERENTIAL...10029
    FINAL DRIVE...10038
    AXLE MOUNTING,CENTER HINGE PIN...10041
    STEERING PIPING...10045
    STEERING COLUMN, ORBIT-ROLL...10046
    STEERING VALVE...10047
    ORBIT-ROLL VALVE...10062
    STOP VALVE...10066
    STEERING PUMP, SWITCH PUMP...10067
    EMERGENCY STEERING PUMP (IF EQUIPPED)...10069
    EMERGENCY STEERING MOTOR (IF EQUIPPED)...10070
    STEERING CYLINDER...10071
    JOYSTICK STEERING LEVER (IF EQUIPPED)...10073
    STEERING LEVER (IF EQUIPPED)...10074
    STEERING SWITCH VALVE (IF EQUIPPED)...10076
    BRAKE PIPING...10077
    BRAKE VALVE...10079
    CHARGE VALVE...10086
    ACCUMULATOR (FOR BRAKE)...10090
    BRAKE...10092
    PARKING BRAKE CONTROL...10097
    PARKING BRAKE...10098
    PARKING BRAKE SOLENOID VALVE...10100
    PARKING BRAKE EMERGENCY RELEASE VALVE...10102
    HYDRAULI PIPING...10103
    WORK EQUIPMENT CONTROL LEVER...10106
    HYDRAULIC TANK...10108
    TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PILOT CONTROL PUMPS...10110
    PPC RELIEF VALVE...10112
    E.C.S.S. VALVE (IF EQUIPPED)...10114
    WORK EQUIPMENT CONTROL VALVE...10116
    WORK EQUIPMENT PPC VALVE...10133
    PPC VALVE (FOR MULTI FUNCTION MONO LEVER)...10139
    EPC SOLENOID VALVE (IF EQUIPPED)...10145
    SHUT OFF VALVE (IF EQUIPPED)...10148
    ATTACHMENT PPC VALVE (IF EQUIPPED)...10149
    COOLING FAN MOTOR...10153
    COOLING FAN MOTOR DRIVE PUMP...10158
    WORK EQUIPMENT LINKAGE...10166
    BUCKET...10168
    BUCKET POSITIONER, LIFT ARM KICK-OUT...10169
    WORK EQUIPMENT CYLINDER...10175
    CAB...10176
    AIR CONDITIONER (IF EQUIPPED)...10177
    MACHINE MONITORING SYSTEM...10178
    MACHINE MONITOR...10185
    TRANSMISSION CONTROL SYSTEM...10251
    TRANSMISSION CONTROLLER...10279
    WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)...10281
    WORK EQUIPMENT CONTROLLER (IF EQUIPPED)...10296
    ELECTRIC TRANSMISSION CONTROL...10298
    KICK DOWN, HOLD SWITCH...10302
    ENGINE STARTING CIRCUIT...10303
    ENGINE STOP CIRCUIT...10305
    PREHEATING CIRCUIT...10306
    ENGINE POWER MODE SELECTOR CIRCUIT...10307
    PARKING BRAKE CIRCUIT...10308
    SENSORS...10312
  20 TESTING AND ADJUSTING...10322
    STANDARD VALUE TABLE FOR ENGINE...10323
    STANDARD VALUE TABLE FOR CHASSIS...10324
    TESTING AND ADJUSTING...10331
      TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...10332
      MEASURING ENGINE SPEED...10333
      MEASURING EXHAUST COLOR...10335
      MEASURING EXHAUST TEMPERATURE...10336
      ADJUSTING VALVE CLEARANCE...10337
      MEASURING COMPRESSION PRESSURE...10339
      MEASURING BLOW-BY PRESSURE...10340
      MEASURING ENGINE OIL PRESSURE...10341
      MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)...10342
      TESTING AND ADJUSTING FUEL INJECTION TIMING...10343
      ADJUSTING ENGINE SPEED SENSOR...10344
      BLEEDING AIR FROM FUEL CIRCUIT...10345
      ADJUSTING ENGINE STOP SOLENOID...10346
      ADJUSTING ACCELERATOR PEDAL...10347
      ADJUSTING TRANSMISSION SPEED SENSOR...10349
      TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE...10350
      DRAWING OF SPECIAL TOOL...10354
      PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT...10355
      PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS...10356
      TESTING AND ADJUSTING STEERING CONTROL...10358
      TESTING AND ADJUSTING STEERING OIL PRESSURE...10359
      TESTING HYDRAULIC FAN...10361
      MEASURING BRAKE OIL PRESSURE...10362
      TESTING WEAR OF WHEEL BRAKE DISC...10364
      BLEEDING AIR FROM BRAKE CIRCUIT...10365
      TESTING WEAR OF PARKING BRAKE DISC...10366
      MANUAL RELEASE METHOD FOR PARKING BRAKE...10367
      TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE...10368
      TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE...10370
      TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE...10372
      TESTING AND ADJUSTING BUCKET POSITIONER...10374
      TESTING AND ADJUSTING LIFT ARM KICK-OUT...10375
      CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP...10376
      ADJUSTING MACHINE MONITOR...10377
      TESTING AND ADJUSTING LOAD METER...10380
      BLEEDING AIR ...10384
      RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...10385
      RELEASING REMAINING PRESSURE IN E.C.S.S. CIRCUIT...10385
      PM CLINIC INSPECTION TABLE...10386
    TROUBLESHOOTING...10388
      POINTS TO REMEMBER WHEN TROUBLESHOOTING...10389
      SEQUENCE OF EVENTS IN TROUBLESHOOTING...10390
      PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...10391
      CHECKS BEFORE TROUBLESHOOTING...10399
      SPECIAL FUNCTIONS OF MACHINE MONITOR...10400
      CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS...10433
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...10441
      T-ADAPTER TABLE...10463
      TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (TM MODE)...10466
        CONNECTOR TYPES AND MOUNTING LOCATIONS...10469
        CONNECTOR LAYOUT DRAWING...10477
        TRANSMISSION CONTROL SYSTEM DIAGRAM...10483
        ERROR CODE [1500L1] (DOUBLE ENGAGEMENT DETECTED) IS DISPLAYED...10486
        ERROR CODE [15SAL1] (F_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED...10487
        ERROR CODE [15SALH] (F_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED...10488
        ERROR CODE [15SBL1] (R_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED...10489
        ERROR CODE [15SBLH] (R_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED...10490
        ERROR CODE [15SEL1] (1ST_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED...10491
        ERROR CODE [15SELH] (1ST_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED...10492
        ERROR CODE [15SFL1] (2ND_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED...10493
        ERROR CODE [15SFLH] (2ND_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED...10494
        ERROR CODE [15SGL1] (3RD_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED...10495
        ERROR CODE [15SGLH] (3RD_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED...10496
        ERROR CODE [15SHL1] (4TH_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED...10497
        ERROR CODE [15SHLH] (4TH_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED...10498
        ERROR CODE [15SJL1] (LOCKUP_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED...10499
        ERROR CODE [15SJLH] (LOCKUP_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED...10500
        ERROR CODE [989F00] (TRANSMISSION PROTECTION CAUTION) IS DISPLAYED...10501
        ERROR CODE [B@C7NS] (REAR BRAKE COOLING OIL OVERHEAT) IS DISPLAYED...10502
        ERROR CODE [D150KA] (EMERGENCY STEERING RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED...10503
        ERROR CODE [D150KB] (EMERGENCY STEERING RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED...10504
        ERROR CODE [D160KA] (BACKUP LAMP RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED...10505
        ERROR CODE [D160KB] (BACKUP LAMP RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED...10506
        ERROR CODE [D191KA] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED...10507
        ERROR CODE [D191KB] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED...10509
        ERROR CODE [D192KA] (E.C.S.S. R RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED...10511
        ERROR CODE [D192KB] (E.C.S.S. RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED...10512
        ERROR CODE [D198KB] (GROUND FAULT IN THE LOW TEMPERATURE BYPASS RELAY SYSTEM) IS DISPLAYED...10513
        ERROR CODE [D198KY] (HOT-SHORT IN THE LOW-TEMPERATURE BYPASS RELAY SYSTEM) IS DISPLAYED...10514
        ERROR CODE [DAQ0KK] (CONTROLLER POWER SUPPLY VOLTAGE LOWERED) IS DISPLAYED...10515
        ERROR CODE [DAQ2KK] (DEFECTIVE SOLENOID POWER SUPPLY SYSTEM) IS DISPLAYED...10516
        ERROR CODE [DAQ9KQ] (MODEL SELECTION SIGNAL MISMATCH) IS DISPLAYED...10517
        ERROR CODE [DDK3KA] (RIGHT FNR SWITCH SIGNAL NOT INPUT) IS DISPLAYED...10518
        ERROR CODE [DDK3KB] (MULTIPLE RIGHT FNR SWITCH SIGNAL INPUT) IS DISPLAYED...10520
        ERROR CODE [DDK4KA] (JOYSTICK FORWARD/REVERSE SWITCH SIGNAL IS NOT INPUT) IS DISPLAYED...10522
        ERROR CODE [DDK4KB] (MULTIPLE JOYSTICK FORWARD/REVERSE SWITCH SIGNALS ARE INPUT) IS DISPLAYED...10524
        ERROR CODE [DDK5LD] (SHORT CIRCUIT WITH POWER SOURCE IN JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH) IS DISPLAYED...10526
        ERROR CODE [DDK6KA] (FORWARD-REVERSE LEVER SIGNAL NOT INPUT) IS DISPLAYED...10527
        ERROR CODE [DDK6KB] (MULTIPLE FORWARD-REVERSE LEVER SIGNAL INPUT) IS DISPLAYED...10529
        ERROR CODE [DDS5KA] (STEERING PRESSURE SWITCH DISCONNECTED) IS DISPLAYED...10531
        ERROR CODE [DDS5KB] (STEERING PRESSURE SWITCH GROUNDED) IS DISPLAYED...10532
        ERROR CODE [DDT0L4] (MANUAL/AUTO-SHIFT SELECTOR SWITCH SELECTION FAILURE) IS DISPLAYED...10533
        ERROR CODE [DDT4LD] (GROUND FAULT OF TRANSMISSION CUT-OFF SETTING SWITCH) IS DISPLAYED...10535
        ERROR CODE [DDW9LD] (GROUND FAULT OF KICKDOWN SWITCH SYSTEM) IS DISPLAYED...10536
        ERROR CODE [DDWLLD] (GROUND FAULT OF HOLD SWITCH SYSTEM) IS DISPLAYED...10538
        ERROR CODE [DF10KA] (NO INPUT OF GEAR SHIFT LEVER SIGNAL) IS DISPLAYED...10540
        ERROR CODE [DF10KB] (INPUT OF MULTIPLE GEAR SHIFT LEVER SIGNALS) IS DISPLAYED...10542
        ERROR CODE [DGF1KX] (TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM FAILURE) IS DISPLAYED...10544
        ERROR CODE [DGR2KA] (REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM DISCONNECTION) IS DISPLAYED...10545
        ERROR CODE [DGR2KB] (GROUND FAULT OF REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED...10546
        ERROR CODE [DHT1KX] (TRANSMISSION CUT-OFF (LEFT BRAKE PRESSURE SENSOR) SIGNAL DISCONTINUITY) IS DISPLAYED...10547
        ERROR CODE [DLE2KA] (ENGINE REVOLUTION SENSOR SYSTEM DISCONTINUITY) IS DISPLAYED...10548
        ERROR CODE [DLE2LC] (ENGINE REVOLUTION SENSOR FAILURE) IS DISPLAYED...10549
        ERROR CODE [DLT3KA] (SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM DISCONTINUITY) IS DISPLAYED...10550
        ERROR CODE [DT20KB] (GROUND FAULT OF BUILT-IN INDICATOR LAMP SYSTEM OF TRANSMISSION CUT-OFF SWITCH) IS DISPLAYED...10551
        ERROR CODE [DW7BKA] (FAN PUMP REVERSE SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...10552
        ERROR CODE [DW7BKB] (FAN PUMP REVERSE SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED...10553
        ERROR CODE [DW7CKA] (SWITCH PUMP CUT-OFF RELAY DISCONTINUITY) IS DISPLAYED...10554
        ERROR CODE [DW7CKB] (SWITCH PUMP CUT-OFF RELAY GROUND FAULT) IS DISPLAYED...10555
        ERROR CODE [DX16KA] (FAN PUMP EPC SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...10556
        ERROR CODE [DX16KB] (FAN PUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...10557
        ERROR CODE [DXH1KA] (LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...10558
        ERROR CODE [DXH1KB] (LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED...10559
        ERROR CODE [DXH4KA] (1ST_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...10560
        ERROR CODE [DXH4KB] (1ST_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED...10561
        ERROR CODE [DXH5KA] (2ND_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...10562
        ERROR CODE [DXH5KB] (2ND_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED...10563
        ERROR CODE [DXH6KA] (3RD_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...10564
        ERROR CODE [DXH6KB] (3RD_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED...10565
        ERROR CODE [DXH7KA] (R_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...10566
        ERROR CODE [DXH7KB] (R_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...10567
        ERROR CODE [DXH8KA] (F_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...10568
        ERROR CODE [DXH8KB] (F_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...10569
        ERROR CODE [DXHHKA] (4TH_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...10570
        ERROR CODE [DXHHKB] (4TH_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED...10571
        ERROR CODE [DY30MA] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE))...10572
        ERROR CODE [DY30MC] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE))...10574
        TROUBLESHOOTING CODE [TM-1] DISCONTINUITY OR HOT SHORT-CIRCUITING OF KICKDOWN SWITCH SYSTEM...10576
        TROUBLESHOOTING CODE [TM-2] HOLD SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING...10578
        TROUBLESHOOTING CODE [TM-3] TORQUE CONVERTER LOCK-UP SWITCH SYSTEM FAILURE...10580
        TROUBLESHOOTING CODE [TM-4] NEUTRALIZER SIGNAL (PARKING BRAKE SWITCH SIGNAL) SYSTEM FAILURE...10581
        TROUBLESHOOTING CODE [TM-5] EMERGENCY STEERING SWITCH (MOTOR-DRIVEN EMERGENCY STEERING OPERATION SWITCH) SIGNAL SYSTEM FAILURE...10583
        TROUBLESHOOTING CODE [TM-6] TRANSMISSION CUT-OFF SWITCH SYSTEM DISCONTINUITY OR GROUND FAULT...10585
        TROUBLESHOOTING CODE [TM-7] TRANSMISSION CUT-OFF SETTING SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING...10586
        TROUBLESHOOTING CODE [TM-8] TRANSMISSION CUT-OFF (LEFT BRAKE SENSOR) SIGNAL SHORT-CIRCUITING...10587
        TROUBLESHOOTING CODE [TM-9a] JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH SYSTEM FAILURE (DISCONTINUITY OR GROUND FAULT)...10588
        TROUBLESHOOTING CODE [TM-9b] JOYSTICK ON/OFF CHANGE OVER SWITCH SYSTEM FAILURE...10589
        TROUBLESHOOTING CODE [TM-10] FNR SWITCH MODE CHANGE OVER SWITCH SYSTEM FAILURE...10591
        TROUBLESHOOTING CODE [TM-11] STARTING SWITCH "C" (IGN_C) SIGNAL SYSTEM FAILURE...10592
        TROUBLESHOOTING CODE [TM-12] ENGINE POWER MODE SWITCH DISCONTINUITY OR GROUND FAULT...10594
        TROUBLESHOOTING CODE [TM-13] TRAVEL DAMPER ON/OFF SWITCH DISCONTINUITY OR GROUND FAULT...10595
        TROUBLESHOOTING CODE [TM-14] HYDRAULIC FAN REVERSE SWITCH SIGNAL SYSTEM HOT SHORT-CIRCUITING OR DISCONTINUITY...10596
        TROUBLESHOOTING CODE [TM-15] MOTOR-DRIVEN EMERGENCY STEERING RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING...10597
        TROUBLESHOOTING CODE [TM-16] TRAVEL DAMPER RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING...10598
        TROUBLESHOOTING CODE [TM-17] SWITCH PUMP CUT-OFF RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING...10599
        TROUBLESHOOTING CODE [TM-18] BACK LAMP RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING...10600
        TROUBLESHOOTING CODE [TM-19] NEUTRAL OUTPUT SYSTEM HOT SHORT-CIRCUITING...10601
        TROUBLESHOOTING CODE [TM-20] FECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING...10602
        TROUBLESHOOTING CODE [TM-21] RECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING...10603
        TROUBLESHOOTING CODE [TM-22] 1ST ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING...10604
        TROUBLESHOOTING CODE [TM-23] 2ND ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING...10605
        TROUBLESHOOTING CODE [TM-24] 3RD ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING...10606
        TROUBLESHOOTING CODE [TM-25] 4TH ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING...10607
        TROUBLESHOOTING CODE [TM-26] LOCK-UP ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING...10608
        TROUBLESHOOTING CODE [TM-27] FAN PUMP EPC SOLENOID SYSTEM HOT SHORT-CIRCUITING...10609
        TROUBLESHOOTING CODE [TM-28] FAN REVERSE SOLENOID SYSTEM HOT SHORT-CIRCUITING...10610
        TROUBLESHOOTING CODE [TM-29] SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM FAILURE...10611
        TROUBLESHOOTING CODE [TM-30] E.C.S.S. SOLENOID SYSTEM DISCONTINUITY OR GROUND FAULT...10612
      TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WRK MODE)...10613
        CONNECTOR TYPES AND MOUNTING LOCATIONS...10616
        CONNECTOR LAYOUT DRAWING...10624
        WORK EQUIPMENT CONTROL SYSTEM DIAGRAM...10632
        FAILURE CODE [D193KA] (DEFECTIVE JOYSTICK STEERING CUT RELAY SYSTEM (MAIN SYSTEM DISCONNECTED)) IS DISPLAYED...10635
        FAILURE CODE [D193KB] (THE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM IS GROUNDED PROPERLY) IS DISPLAYED...10636
        FAILURE CODE [DB90KK] (LOWERING WORK EQUIPMENT CONTROLLER POWER SUPPLY) IS DISPLAYED...10637
        FAILURE CODE [DB92KK] (DEFECTIVE SOLENOID ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED...10638
        FAILURE CODE [DB95KX] (DEFECTIVE 5 V ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED...10639
        FAILURE CODE [DD1ALD] (DEFECTIVE REMOTE POSITIONER UP SET SWITCH (GROUND FAULT)) IS DISPLAYED...10641
        FAILURE CODE [DD1BLD] (DEFECTIVE REMOTE POSITIONER DOWN SET SWITCH (GROUND FAULT)) IS DISPLAYED...10642
        FAILURE CODE [DFA0KM] (DEFECTIVE NEUTRAL CAUTION FOR JOYSTICK WORK EQUIPMENT LEVER) IS DISPLAYED...10643
        FAILURE CODE [DK59KA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED...10644
        FAILURE CODE [DK59KY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORT CIRCUIT)) IS DISPLAYED...10645
        FAILURE CODE [DK59L8] (DEFECTIVE LIFT ARM EPC POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED...10646
        FAILURE CODE [DK5AKA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OF MAIN) (DISCONNECTION,GROUND OF SUB)) IS DISPLAYED...10647
        FAILURE CODE [DK5AKY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED...10648
        FAILURE CODE [DK5BKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED...10649
        FAILURE CODE [DK5BKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORTED)) IS DISPLAYED...10650
        FAILURE CODE [DK5BL8] (DEFECTIVE INPUT SIGNAL FOR BUCKET EPC LEVER POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED...10651
        FAILURE CODE [DK5CKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED...10652
        FAILURE CODE [DK5CKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED...10653
        FAILURE CODE [DK5DKA] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED...10654
        FAILURE CODE [DK5DKY] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORT CIRCUIT)) IS DISPLAYED...10655
        FAILURE CODE [DK5DL8] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED...10656
        FAILURE CODE [DK5EKA] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED...10657
        FAILURE CODE [DK5EKY] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED...10658
        FAILURE CODE [DK5FKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED...10659
        FAILURE CODE [DK5FKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORTED)) IS DISPLAYED...10660
        FAILURE CODE [DK5FKM] (JOYSTICK STEERING EPC LEVER NEUTRAL SYSTEM CAUTION) IS DISPLAYED...10661
        FAILURE CODE [DK5FL8] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DEVIATION OF POSITIONAL SIGNALS OF MAIN AND SUB-CIRCUITS)) IS DISPLAYED...10662
        FAILURE CODE [DG5GKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUND FAULT OF SUB-CIRCUIT)) IS DISPLAYED...10663
        FAILURE CODE [DK5GKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT SHORT CIRCUIT)) IS DISPLAYED...10664
        FAILURE CODE [DKA0KA] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (DISCONNECTION OR GROUND FAULT)) IS DISPLAYED...10665
        FAILURE CODE [DKA0KY] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (SHORT CIRCUIT)) IS DISPLAYED...10666
        FAILURE CODE [DLE2LC] (DEFECTIVE ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED...10667
        FAILURE CODE [DLT3LC] (DEFECTIVE TRANSMISSION OUTPUT AXIS SPEED SENSOR SYSTEM (DISCONNECTED)) IS DISPLAYED...10668
        FAILURE CODE [DUM1KB] (REMOTE POSITIONER RAISE LAMP SYSTEM GROUND FAULT) IS DISPLAYED...10669
        FAILURE CODE [DUM2KB] (REMOTE POSITIONER LOWER LAMP SYSTEM GROUND FAULT) IS DISPLAYED...10670
        FAILURE CODE [DW4PKA] (DISCONNECTED LIFT ARM RAISE EPC SOLENOID SYSTEM) IS DISPLAYED...10671
        FAILURE CODE [DW4PKB] (LIFT ARM RAISE EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...10672
        FAILURE CODE [DW4QKA] (DISCONNECTED LIFT ARM LOWER EPC SOLENOID SYSTEM) IS DISPLAYED...10673
        FAILURE CODE [DW4QKB] (LIFT ARM LOWER EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...10674
        FAILURE CODE [DW4RKA] (DISCONNECTED BUCKET TILT EPC SOLENOID SYSTEM) IS DISPLAYED...10675
        FAILURE CODE [DW4RKB] (BUCKET TILT EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...10676
        FAILURE CODE [DW4SKA] (BUCKET DUMP EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED...10677
        FAILURE CODE [DW4SKB] (BUCKET DUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...10678
        FAILURE CODE [DWM1KA] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED...10679
        FAILURE CODE [DWM1KB] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...10680
        FAILURE CODE [DWN6KA] (LIFT ARM RAISE MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED...10681
        FAILURE CODE [DWN6KB] (LIFT ARM RAISE MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED...10682
        FAILURE CODE [DWN7KA] (LIFT ARM FLOATING MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED...10683
        FAILURE CODE [DWN7KB] (LIFT ARM FLOATING MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED...10684
        FAILURE CODE [DWN8KA] (BUCKET TILT MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED...10685
        FAILURE CODE [DWN8KB] (BUCKET TILT MAGNET DETENT SYSTEM FAILURE (POWER SUPPLY SYSTEM GROUND FAULT)) IS DISPLAYED...10686
        FAILURE CODE [DXHJKA] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED...10687
        FAILURE CODE [DXHJKB] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...10688
        FAILURE CODE [DXHKKA] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED...10689
        FAILURE CODE [DXHKKB] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...10690
        FAILURE CODE [DXHLKA] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED...10691
        FAILURE CODE [DXHLKB] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...10692
        FAILURE CODE [DXHMKA] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED...10693
        FAILURE CODE [DXHMKB] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...10694
        TROUBLESHOOTING CODE [WRK-1] DEFECTIVE LIFT ARM LOCK SWITCH SYSTEM...10695
        TROUBLESHOOTING CODE [WRK-2] DEFECTIVE REMOTE POSITIONER RAISE SETTING SWITCH SYSTEM...10696
        TROUBLESHOOTING CODE [WRK-3] DEFECTIVE REMOTE POSITIONER LOWER SETTING SWITCH SYSTEM...10697
        TROUBLESHOOTING CODE [WRK-4] DEFECTIVE REMOTE POSITIONER RAISE SELECTION SWITCH SYSTEM...10699
        TROUBLESHOOTING CODE [WRK-5] DEFECTIVE REMOTE POSITIONER LOWER ON/OFF SWITCH SYSTEM...10701
        TROUBLESHOOTING CODE [WRK-6] DEFECTIVE BUCKET CYLINDER PROXIMITY SWITCH SYSTEM...10703
        TROUBLESHOOTING CODE [WRK-7] DEFECTIVE BUCKET CYLINDER FULL STROKE DETECTION SWITCH SYSTEM...10705
        TROUBLESHOOTING CODE [WRK-8] DEFECTIVE SEMI-AUTOMATIC DIGGING HARD SELECTION SWITCH SYSTEM...10706
        TROUBLESHOOTING CODE [WRK-9] DEFECTIVE SEMI-AUTOMATIC DIGGING SOFT SELECTION SWITCH SYSTEM...10707
        TROUBLESHOOTING CODE [WRK-10] DEFECTIVE JOYSTICK ON/OFF SWITCH SYSTEM...10708
        TROUBLESHOOTING CODE [WRK-11] DEFECTIVE JOYSTICK STEERING SPEED HI/LO SWITCH SYSTEM...10710
        TROUBLESHOOTING CODE [WRK-12] DEFECTIVE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM...10711
        TROUBLESHOOTING CODE [WRK-13] HOT SHORT-CIRCUITED LIFT ARM RAISE MAGNET DETENT OUTPUT SYSTEM...10712
        TROUBLESHOOTING CODE [WRK-14] HOT SHORT-CIRCUITED LIFT ARM FLOATING MAGNET DETENT OUTPUT SYSTEM...10713
        TROUBLESHOOTING CODE [WRK-15] HOT SHORT-CIRCUITED BUCKET TILT MAGNET DETENT OUTPUT SYSTEM...10714
        TROUBLESHOOTING CODE [WRK-16] HOT SHORT-CIRCUITED WORK EQUIPMENT NEUTRAL LOCK SOLENOID OUTPUT SYSTEM...10715
        TROUBLESHOOTING CODE [WRK-17] HOT SHORT-CIRCUITED LIFT ARM RAISE EPC SOLENOID SYSTEM...10716
        TROUBLESHOOTING CODE [WRK-18] HOT SHORT-CIRCUITED LIFT ARM LOWER EPC SOLENOID SYSTEM...10717
        TROUBLESHOOTING CODE [WRK-19] HOT SHORT-CIRCUITED BUCKET TILT EPC SOLENOID SYSTEM...10718
        TROUBLESHOOTING CODE [WRK-20] HOT SHORT-CIRCUITED BUCKET DUMP EPC SOLENOID SYSTEM...10719
        TROUBLESHOOTING CODE [WRK-21] HOT SHORT-CIRCUITED 3 VALVES EXTENSION EPC SOLENOID SYSTEM...10720
        TROUBLESHOOTING CODE [WRK-22] HOT SHORT-CIRCUITED 3 VALVES RETRACTION EPC SOLENOID SYSTEM...10721
        TROUBLESHOOTING CODE [WRK-23] HOT SHORT-CIRCUITED JOYSTICK STEERING RIGHT EPC SOLENOID SYSTEM...10722
        TROUBLESHOOTING CODE [WRK-24] HOT SHORT-CIRCUITED JOYSTICK STEERING LEFT EPC SOLENOID SYSTEM...10723
        TROUBLESHOOTING CODE [WRK-25] DEFECTIVE BUCKET POSITIONER, LIFT ARM KICK-OUT AND FLOATING HOLDING FUNCTION...10724
        TROUBLESHOOTING CODE [WRK-26] DEFECTIVE LIFT ARM KICK-OUT FUNCTION AND CANCELLATION...10726
        TROUBLESHOOTING CODE [WRK-27] DEFECTIVE BUCKET LEVELER FUNCTION AND CANCELLATION...10728
        TROUBLESHOOTING CODE [WRK-28] DEFECTIVE LIFT ARM FLOATING HOLDING AND CANCELLATION...10730
      TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE)...10731
        CONNECTOR TYPES AND MOUNTING LOCATIONS...10733
        CONNECTOR LAYOUT DRAWING...10741
        MONITOR SYSTEM DIAGRAM...10747
        FAILURE CODE [2F00MA] DRAGGING OF PARKING BRAKE...10751
        FAILURE CODE [2G42ZG] ACCUMULATOR OIL PRESSURE (FRONT CIRCUIT) LOW...10753
        FAILURE CODE [2G43ZG] ACCUMULATOR OIL PRESSURE (REAR BRAKE CIRCUIT) LOW...10754
        FAILURE CODE [AA1ANX] AIR CLEANER 1 CLOGGED...10755
        FAILURE CODE [AB00L6] DEFECTIVE BATTERY CHARGING CIRCUIT (ALTERNATOR TERMINAL R SIGNAL DETECTED WHEN ENGINE STOPPED...10757
        FAILURE CODE [AB00MA] DEFECTIVE BATTERY CHARGING CIRCUIT (NO ALTERNATOR TERMINAL R SIGNAL DETECTED, DETECTION FAILURE)...10758
        FAILURE CODE [B@BAZG] ENGINE OIL PRESSURE LOW...10759
        FAILURE CODE [B@BAZK] ENGINE OIL LEVEL LOW...10760
        FAILURE CODE [B@BCNS] ENGINE WATER TEMPERATURE OVERHEATING...10761
        FAILURE CODE [B@BCZK] ALARM INDICATING LOW COOLANT LEVEL...10762
        FAILURE CODE [B@HANS] HYDRAULIC OIL TEMPERATURE OVERHEATING...10763
        FAILURE CODE [B@CENS] TORQUE CONVERTER OIL TEMPERATURE OVERHEATING...10764
        FAILURE CODE [D182KZ] THE PREHEATER RELAY COIL IS DISCONNECTED OR SHIRT-CIRCUITED...10765
        FAILURE CODE [D5ZHL6] STARTING SWITCH C (IGN"C") INPUT FAILURE...10767
        FAILURE CODE [DA80L4] AUTO GREASE INPUT FAILURE...10768
        FAILURE CODE [DAF3KK] SW POWER SUPPLY (FOR OPERATION) = ON AND NSW POWER SUPPLY (FOR MEMORY) IS OFF...10769
        FAILURE CODE [DAF5KP] 5V POWER SUPPLY OUTPUT FAILURE...10771
        FAILURE CODE [DAF6KP] 24V POWER SUPPLY OUTPUT FAILURE...10772
        FAILURE CODE [DAFBKM] WRONG INFORMATION ON MODEL SELECTION...10774
        FAILURE CODE [DAFSKQ] WRONG INFORMATION ON METER DISPLAY SELECTION...10775
        FAILURE CODE [DAQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND TRANSMISSION CONTROLLER) ...10776
        FAILURE CODE [DBQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) ...10777
        FAILURE CODE [DB9SKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) ...10778
        FAILURE CODE [DD15LD] MONITOR PANEL MODE SELECTOR SWITCH 1 (PANEL SW1) INPUT ERROR...10779
        FAILURE CODE [DD16LD] MONITOR PANEL MODE SELECTOR SWITCH 1 (PANEL SW2) INPUT ERROR...10780
        FAILURE CODE [DD17LD] THE MONITOR PANEL MODE SELECTOR SWITCH 2 (PANEL SW3) INPUT CIRCUIT REMAINS CLOSED FOR MORE THAN ONE MINUTE...10781
        FAILURE CODE [DD18LD] MONITOR PANEL MODE SELECTOR SWITCH 2 (PANEL SW4) INPUT ERROR...10782
        FAILURE CODE [DD1CLD] SUB-TOTAL SWITCH FAILURE...10783
        FAILURE CODE [DDS5L6] DECREASED STEERING OIL PRESSURE...10785
        FAILURE CODE [DDY0LD] CANCEL SWITCH FAILURE...10787
        FAILURE CODE [DGE2KX] ENGINE WATER TEMPERATURE SENSOR SYSTEM FAILURE...10789
        FAILURE CODE [DGE3L6] ABNORMAL CONNECTION OF ENGINE WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM...10790
        FAILURE CODE [DGH2KX] HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM FAILURE...10791
        FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM FAILURE...10792
        FAILURE CODE [DHE4L6] ENGINE OIL PRESSURE SENSOR SYSTEM FAILURE...10793
        FAILURE CODE [DHPCKX] BOTTOM PRESSURE SENSOR FAILURE...10794
        FAILURE CODE [DHPDKX] HEAD PRESSURE SENSOR FAILURE...10796
        FAILURE CODE [DKA0KX] LIFT ARM ANGLE SENSOR FAILURE...10798
        FAILURE CODE [DV00KB] SHORT-CIRCUITED ALARM BUZZER OUTPUT SYSTEM...10799
        FAILURE CODE [DY30ME] THE EMERGENCY STEERING REMAINS ACTUATED FOR MORE THAN ONE MINUTE...10800
        TROUBLESHOOTING CODE [MON-1] THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT UP WHEN THE PARKING BRAKE SWITCH IS TURNED ON (THE PARKING BRAKE INDICATOR SWITCH CIRCUIT SUFFERS A GROUND FAULT)...10802
        TROUBLESHOOTING CODE [MON-2] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (FRONT CIRCUIT)...10804
        TROUBLESHOOTING CODE [MON-3] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (REAR CIRCUIT)...10805
        TROUBLESHOOTING CODE [MON-4] THE AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT ON...10806
        TROUBLESHOOTING CODE [MON-5] THE ENGINE HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON...10808
        TROUBLESHOOTING CODE [MON-6] THE ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT ON...10809
        TROUBLESHOOTING CODE [MON-7] THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON...10810
        TROUBLESHOOTING CODE [MON-8] THE RADIATOR WATER VOLUME CAUTION LAMP DOES NOT LIGHT ON...10811
        TROUBLESHOOTING CODE [MON-9] THE HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON...10812
        TROUBLESHOOTING CODE [MON-10] THE TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON...10813
        TROUBLESHOOTING CODE [MON-11] THE STEERING HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON...10814
        TROUBLESHOOTING CODE [MON-12] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW1)...10815
        TROUBLESHOOTING CODE [MON-13] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW2)...10816
        TROUBLESHOOTING CODE [MON-14] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW3)...10817
        TROUBLESHOOTING CODE [MON-15] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW4)...10818
        TROUBLESHOOTING CODE [MON-16] DEFECTIVE SUBTOTAL SWITCH...10819
        TROUBLESHOOTING CODE [MON-17] DEFECTIVE CANCEL SWITCH...10820
        TROUBLESHOOTING CODE [MON-18] DEFECTIVE BOTTOM PRESSURE SENSOR (HOT SHORT FAULT)...10821
        TROUBLESHOOTING CODE [MON-19] DEFECTIVE HEAD SENSOR...10822
        TROUBLESHOOTING CODE [MON-20] THE ALARM BUZZER DOES NOT SOUND OR STOP (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN BUZZER OUTPUT SYSTEM)...10823
      TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)...10824
        H-1 THE MACHINE DOES NOT START...10825
        H-2 THE LOCK-UP CLUTCH IS NOT RELEASED (THE ENGINE STOPS) (WHEN THE LOCK-UP CLUTCH IS PROVIDED)...10827
        H-3...10828
          a. THE TRAVEL SPEED IS SLOW, THE THRUSTING FORCE IS WEAK, THE UPHILL TRAVELING POWER IS WEAK, AND THE GEAR IS NOT SHIFTED...10828
          b. THE TORQUE CONVERTER LOCK-UP CLUTCH IS NOT LET IN (IF THE LOCK-UP CLUTCH IS EQUIPPED)...10830
        H-4 SHOCKS ARE LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR...10831
        H-5 TIME LAG IS LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR...10833
        H-6 THE TORQUE CONVERTER OIL TEMPERATURE IS HIGH...10835
        H-7 THE STEERING WHEEL DOES NOT TURN...10836
        H-8 THE STEERING WHEEL IS HEAVY...10837
        H-9 THE STEERING WHEEL FLUCTUATES OR IS STRONGLY SHOCKED ...10838
        H-10 THE MACHINE STEERS TO ONE SIDE WHEN STAVELING...10838
        H-11 THE RIGHT AND LEFT SWING RADII ARE DIFFERENT...10838
        H-12 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL...10839
        H-13 THE BRAKE IS NOT RELEASED OR IS DRAGGED...10840
        H-14 THE BRAKE IS NOT RELEASED OR DRAGGED...10841
        H-15 THE LIFT ARM DOES NOT RISE...10842
        H-16 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT...10843
        H-17 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT...10844
        H-18 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR)...10844
        H-19 HYDRAULIC DRIFTS OF THE BOOM OCCUR OFTEN...10844
        H-20 THE LIFT ARM WOBBLES DURING OPERATION...10844
        H-21 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "RAISE", THE LIFT ARM FALLS TEMPORARILY...10845
        H-22 THE BUCKET DOES NOT TILT BACK...10846
        H-23 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT...10847
        H-24 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILTING-BACK...10848
        H-25 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET...10848
        H-26 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN...10848
        H-27 THE BUCKET WOBBLES DURING TRAVEL CARGO (THE WORK EQUIPMENT VALVE IS SET TO "HOLD")...10849
        H-28 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "TILT", THE BUCKET FALLS TEMPORARILY...10849
        H-29 THE CONTROL LEVERS OF LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY...10850
        H-30 E.C.S.S. DOES NOT WORK, AND THERE IS PITCING AND BOUNCING...10851
      TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...10852
        CONNECTOR TYPES AND MOUNTING LOCATIONS...10853
        CONNECTOR LAYOUT DRAWING...10861
        ELECTRICAL SYSTEM DIAGRAM...10867
        TROUBLESHOOTING CODE [E-1-a] (THE ENGINE DOES NOT START. (STARTING SYSTEM))...10868
        TROUBLESHOOTING CODE [E-1-b] (THE ENGINE DOES NOT START. (ENGINE STOP SOLENOID SYSTEM))...10872
        TROUBLESHOOTING CODE [E-2] (THE ENGINE DOES NOT STOP)...10874
        TROUBLESHOOTING CODE [E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT)...10876
        TROUBLESHOOTING CODE [E-4] (THE ENGINE POWER MODES CANNOT BE SELECTED)...10878
        TROUBLESHOOTING CODE [E-5] (THE FRONT WIPER DOES NOT FUNCTION)...10880
        TROUBLESHOOTING CODE [E-6] (THE REAR WIPER DOES NOT FUNCTION)...10883
        TROUBLESHOOTING CODE [E-7] (THE SIDE WIPER DOES NOT FUNCTION (IF EQUIPPED))...10884
        TROUBLESHOOTING CODE [E-8] (THE WIND WASHER DOES NOT FUNCTION)...10885
        TROUBLESHOOTING CODE [E-9] (THE HEADLAMP (LO BEAM) DOES NOT LIGHT ON)...10888
        TROUBLESHOOTING CODE [E-10] (THE HEADLAMP (HI BEAM) DOES NOT FUNCTION)...10891
        TROUBLESHOOTING CODE [E-11] (THE CLEARANCE LAMP DOES NOT LIGHT ON (SMALL LAMP))...10893
        TROUBLESHOOTING CODE [E-12] (THE TURN SIGNAL DOES NOT BLINK)...10894
        TROUBLESHOOTING CODE [E-13] (THE HORN DOES NOT SOUND)...10896
        TROUBLESHOOTING CODE [E-14] (THE AIR CONDITIONER DOES NOT WORK OR DOES NOT STOP)...10898
      TROUBLESHOOTING OF ENGINE (S MODE)...10901
        METHOD OF USING TROUBLESHOOTING CHARTS...10902
        S-1 STARTING PREFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...10906
        S-2 ENGINE DOES NOT START...10907
          (1) ENGINE DOES NOT TURN...10907
          (2) ENGINE TURN BUT NO EXHAUST SMOKE COMES OUT (FUEL IS BEING INJECTED)...10908
          (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...10909
        S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...10910
        S-4 ENGINE STOPS DURING OPERATIONS...10911
        S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...10912
        S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...10913
        S-7 EXHAUST SMOKE IS BLACK (INCOMPLATE COMBUSTION)...10914
        S-8 OIL CONSUMPTION IS ESCESSIVE (OR EXHAUST SMOKE IS BLUE)...10915
        S-9 OIL BECOMES CONTAMINATED QUICKLY...10916
        S-10 FUEL CONSUMPTION IS EXCESSIVE...10917
        S-11 OIL IS IN COOLING COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN...10918
        S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...10919
        S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...10920
        S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...10921
        S-15 ABNORMAL NOISE IS MADE...10922
        S-16 VIBRATION IS EXCESSIVE...10923
  30 DISASSEMBLY AND ASSEMBLY...10924
    METHOD OF USING MANUAL...10925
    PRECAUTIONS WHEN CARRYING OUT OPERATION...10927
    SPECIAL TOOL LIST...10929
    REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY...10941
    REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY...10945
    REMOVAL AND INSTALLATION OF RADIATOR AND FAN MOTOR ASSEMBLY...10950
    REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY...10952
    REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP...10952
    REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY...10955
    REMOVAL AND INSTALLATION OF FAN AND MOTOR ASSEMBLY...10957
    REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY...10958
    REMOVAL AND INSTALLATION OF PARKING BRAKE DISC PLATE...10960
    REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...10963
    DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY...10967
    DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH PACK ASSEMBLY...10979
    DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY...10994
    DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (STANDARD SPECIFICATION)...11002
    DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (LOCK-UP SPECIFICATION)...11006
    REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY...11012
    REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY...11015
    DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY...11016
    DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY...11024
    REMOVAL AND INSTALLATION OF CENTER HINGE PIN...11043
    REMOVAL AND INSTALLATION OF CAB ASSEMBLY...11050
    REMOVAL AND INSTALLATION OF CAB AND FLOOR FRAME ASSEMBLY...11051
    REMOVAL AND INSTALLATION OF TRANSMISSION OF OPERATOR'S CAB GLASS (STUCK GLASS)...11054
    REMOVAL AND INSTALLATION OF TRANSMISSION, WORK EQUIPMENT, AND PPC PUMP ASSEMBLY...11062
    REMOVAL AND INSTALLATION OF STEERING, SWITCHING, AND FAN PUMP ASSEMBLY...11063
    REMOVAL AND INSTALLATION OF STEERING DEMAND VALVE ASSEMBLY...11064
    REMOVAL AND INSTALLATION OF E.C.S.S. VALVE ASSEMBLY...11065
    REMOVAL AND INSTALLATION OF WORK EQUIPMENT VALVE ASSEMBLY...11066
    DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY (STEERING, LIFT, AND BUCKET CYLINDER ASSEMBLY)...11068
    REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY...11076
    REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY...11078
    REMOVAL AND INSTALLATION OF COUNTER WEIGHT...11082
    REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY...11083
    REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY...11086
    DISASSEMBLY, ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY...11087
  90 OTHERS...11097
    POWER TRAIN OIL CIRCUIT DIAGRAM (WITHOUT TORQUE CONVERTER LOCKUP CLUTCH)...11098
    POWER TRAIN OIL CIRCUIT DIAGRAM (WITH TORQUE CONVERTER LOCKUP CLUTCH)...11099
    BRAKE OIL CIRCUIT DIAGRAM...11100
    WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...11101
    WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (FOR ELECTRIC WORK EQUIPMENT LEVER)...11102
    ELECTRICAL CIRCUIT DIAGRAM...11103
      1/8 (1/4)...11103
      1/8 (2/4)...11104
      1/8 (3/4)...11105
      1/8 (4/4)...11106
      2/8 (1/4)...11107
      2/8 (2/4)...11108
      2/8 (3/4)...11109
      2/8 (4/4)...11110
      3/8...11111
      4/8...11112
      5/8...11113
      6/8...11114
      7/8...11115
      8/8...11116
SEBM024712 - Wheel Loader WA380-5 Shop Manual...11117
  COVER...11117
  CONTENTS...11118
  01 GENERAL...11145
    GENERAL ASSEMBLY DRAWING...11146
    SPECIFICATIONS...11147
    WEIGHT TABLE...11151
    LIST OF LUBRICANT AND COOLANT...11153
  10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD...11155
    COOLING SYSTEM...11156
    ENGINE MOUNT, TRANSMISSION MOUNT...11157
    POWER TRAIN...11158
    POWER TRAIN SYSTEM DIAGRAM...11159
    DRIVE SHAFT (PROPELLER SHAFT)...11162
    TORQUE CONVERTER, TRANSMISSION PIPING...11163
    TORQUE CONVERTER...11164
    TRANSMISSION...11172
    TRANSMISSION CONTROL VALVE...11188
    AXLE...11206
    DIFFERENTIAL...11208
    FINAL DRIVE...11217
    AXLE MOUNTING,CENTER HINGE PIN...11220
    STEERING PIPING...11224
    STEERING COLUMN, ORBIT-ROLL...11225
    STEERING VALVE...11226
    ORBIT-ROLL VALVE...11241
    STOP VALVE...11245
    STEERING PUMP, SWITCH PUMP...11246
    EMERGENCY STEERING PUMP (IF EQUIPPED)...11248
    EMERGENCY STEERING MOTOR (IF EQUIPPED)...11249
    STEERING CYLINDER...11250
    JOYSTICK STEERING LEVER (IF EQUIPPED)...11252
    STEERING LEVER (IF EQUIPPED)...11253
    STEERING SWITCH VALVE (IF EQUIPPED)...11255
    BRAKE PIPING...11256
    BRAKE VALVE...11258
    CHARGE VALVE...11265
    ACCUMULATOR (FOR BRAKE)...11269
    BRAKE...11271
    PARKING BRAKE CONTROL...11276
    PARKING BRAKE...11277
    PARKING BRAKE SOLENOID VALVE...11279
    PARKING BRAKE EMERGENCY RELEASE VALVE...11281
    HYDRAULI PIPING...11282
    WORK EQUIPMENT CONTROL LEVER...11285
    HYDRAULIC TANK...11287
    TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PILOT CONTROL PUMPS...11289
    PPC RELIEF VALVE...11291
    E.C.S.S. VALVE (IF EQUIPPED)...11293
    WORK EQUIPMENT CONTROL VALVE...11295
    WORK EQUIPMENT PPC VALVE...11312
    PPC VALVE (FOR MULTI FUNCTION MONO LEVER)...11318
    EPC SOLENOID VALVE (IF EQUIPPED)...11324
    SHUT OFF VALVE (IF EQUIPPED)...11327
    ATTACHMENT PPC VALVE (IF EQUIPPED)...11328
    COOLING FAN MOTOR...11332
    COOLING FAN MOTOR DRIVE PUMP...11337
    WORK EQUIPMENT LINKAGE...11345
    BUCKET...11347
    BUCKET POSITIONER, LIFT ARM KICK-OUT...11348
    WORK EQUIPMENT CYLINDER...11354
    CAB...11355
    AIR CONDITIONER (IF EQUIPPED)...11356
    MACHINE MONITORING SYSTEM...11357
    MACHINE MONITOR...11364
    TRANSMISSION CONTROL SYSTEM...11434
    TRANSMISSION CONTROLLER...11462
    WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)...11464
    WORK EQUIPMENT CONTROLLER (IF EQUIPPED)...11480
    ELECTRIC TRANSMISSION CONTROL...11482
    KICK DOWN, HOLD SWITCH...11486
    ENGINE STARTING CIRCUIT...11487
    ENGINE STOP CIRCUIT...11489
    PREHEATING CIRCUIT...11490
    ENGINE POWER MODE SELECTOR CIRCUIT...11491
    PARKING BRAKE CIRCUIT...11492
    SENSORS...11496
  20 TESTING AND ADJUSTING...11507
    STANDARD VALUE TABLE FOR ENGINE...11508
    STANDARD VALUE TABLE FOR CHASSIS...11509
    TESTING AND ADJUSTING...11517
      TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...11519
      MEASURING ENGINE SPEED...11520
      MEASURING EXHAUST COLOR...11522
      MEASURING EXHAUST TEMPERATURE...11523
      ADJUSTING VALVE CLEARANCE...11524
      MEASURING COMPRESSION PRESSURE...11526
      MEASURING BLOW-BY PRESSURE...11527
      MEASURING ENGINE OIL PRESSURE...11528
      MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)...11529
      TESTING AND ADJUSTING FUEL INJECTION TIMING...11530
      ADJUSTING ENGINE SPEED SENSOR...11531
      BLEEDING AIR FROM FUEL CIRCUIT...11532
      ADJUSTING ENGINE STOP SOLENOID...11533
      ADJUSTING ACCELERATOR PEDAL...11535
      ADJUSTING TRANSMISSION SPEED SENSOR...11537
      TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE...11538
      DRAWING OF SPECIAL TOOL...11542
      PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT...11543
      PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS...11544
      TESTING AND ADJUSTING STEERING CONTROL...11546
      TESTING AND ADJUSTING STEERING OIL PRESSURE...11547
      TESTING HYDRAULIC FAN...11549
      MEASURING BRAKE OIL PRESSURE...11550
      TESTING WEAR OF WHEEL BRAKE DISC...11552
      BLEEDING AIR FROM BRAKE CIRCUIT...11553
      TESTING WEAR OF PARKING BRAKE DISC...11554
      MANUAL RELEASE METHOD FOR PARKING BRAKE...11555
      TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE...11556
      TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE...11558
      TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE...11560
      TESTING AND ADJUSTING BUCKET POSITIONER...11562
      TESTING AND ADJUSTING LIFT ARM KICK-OUT...11563
      CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP...11564
      ADJUSTING MACHINE MONITOR...11565
      TESTING AND ADJUSTING LOAD METER...11568
      BLEEDING AIR ...11572
      RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...11573
      RELEASING REMAINING PRESSURE IN E.C.S.S. CIRCUIT...11573
      PM CLINIC INSPECTION TABLE...11574
    TROUBLESHOOTING...11577
      POINTS TO REMEMBER WHEN TROUBLESHOOTING...11578
      SEQUENCE OF EVENTS IN TROUBLESHOOTING...11579
      PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...11580
      CHECKS BEFORE TROUBLESHOOTING...11588
      SPECIAL FUNCTIONS OF MACHINE MONITOR...11590
      CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS...11625
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...11634
      T-ADAPTER TABLE...11657
      TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (TM MODE)...11661
        CONNECTOR TYPES AND MOUNTING LOCATIONS...11665
        CONNECTOR LAYOUT DRAWING...11674
        TRANSMISSION CONTROL SYSTEM DIAGRAM...11680
        ERROR CODE [1500L1] (DOUBLE ENGAGEMENT DETECTED) IS DISPLAYED...11683
        ERROR CODE [15SAL1] (F_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED...11684
        ERROR CODE [15SALH] (F_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED...11685
        ERROR CODE [15SBL1] (R_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED...11686
        ERROR CODE [15SBLH] (R_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED...11687
        ERROR CODE [15SEL1] (1ST_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED...11688
        ERROR CODE [15SELH] (1ST_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED...11689
        ERROR CODE [15SFL1] (2ND_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED...11690
        ERROR CODE [15SFLH] (2ND_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED...11691
        ERROR CODE [15SGL1] (3RD_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED...11692
        ERROR CODE [15SGLH] (3RD_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED...11693
        ERROR CODE [15SHL1] (4TH_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED...11694
        ERROR CODE [15SHLH] (4TH_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED...11695
        ERROR CODE [15SJL1] (LOCKUP_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED...11696
        ERROR CODE [15SJLH] (LOCKUP_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED...11697
        ERROR CODE [989F00] (TRANSMISSION PROTECTION CAUTION) IS DISPLAYED...11698
        ERROR CODE [B@C7NS] (REAR BRAKE COOLING OIL OVERHEAT) IS DISPLAYED...11700
        ERROR CODE [D150KA] (EMERGENCY STEERING RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED...11701
        ERROR CODE [D150KB] (EMERGENCY STEERING RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED...11702
        ERROR CODE [D160KA] (BACKUP LAMP RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED...11703
        ERROR CODE [D160KB] (BACKUP LAMP RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED...11704
        ERROR CODE [D191KA] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED...11706
        ERROR CODE [D191KB] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED...11708
        ERROR CODE [D192KA] (E.C.S.S. R RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED...11710
        ERROR CODE [D192KB] (E.C.S.S. RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED...11711
        ERROR CODE [D198KB] (GROUND FAULT IN THE LOW TEMPERATURE BYPASS RELAY SYSTEM) IS DISPLAYED...11712
        ERROR CODE [D198KY] (HOT-SHORT IN THE LOW-TEMPERATURE BYPASS RELAY SYSTEM) IS DISPLAYED...11713
        ERROR CODE [DAQ0KK] (CONTROLLER POWER SUPPLY VOLTAGE LOWERED) IS DISPLAYED...11714
        ERROR CODE [DAQ2KK] (DEFECTIVE SOLENOID POWER SUPPLY SYSTEM) IS DISPLAYED...11715
        ERROR CODE [DAQ9KQ] (MODEL SELECTION SIGNAL MISMATCH) IS DISPLAYED...11716
        ERROR CODE [DDK3KA] (RIGHT FNR SWITCH SIGNAL NOT INPUT) IS DISPLAYED...11718
        ERROR CODE [DDK3KB] (MULTIPLE RIGHT FNR SWITCH SIGNAL INPUT) IS DISPLAYED...11720
        ERROR CODE [DDK4KA] (JOYSTICK FORWARD/REVERSE SWITCH SIGNAL IS NOT INPUT) IS DISPLAYED...11723
        ERROR CODE [DDK4KB] (MULTIPLE JOYSTICK FORWARD/REVERSE SWITCH SIGNALS ARE INPUT) IS DISPLAYED...11725
        ERROR CODE [DDK5LD] (SHORT CIRCUIT WITH POWER SOURCE IN JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH) IS DISPLAYED...11727
        ERROR CODE [DDK6KA] (FORWARD-REVERSE LEVER SIGNAL NOT INPUT) IS DISPLAYED...11728
        ERROR CODE [DDK6KB] (MULTIPLE FORWARD-REVERSE LEVER SIGNAL INPUT) IS DISPLAYED...11730
        ERROR CODE [DDS5KA] (STEERING PRESSURE SWITCH DISCONNECTED) IS DISPLAYED...11732
        ERROR CODE [DDS5KB] (STEERING PRESSURE SWITCH GROUNDED) IS DISPLAYED...11733
        ERROR CODE [DDT0L4] (MANUAL/AUTO-SHIFT SELECTOR SWITCH SELECTION FAILURE) IS DISPLAYED...11734
        ERROR CODE [DDT4LD] (GROUND FAULT OF TRANSMISSION CUT-OFF SETTING SWITCH) IS DISPLAYED...11736
        ERROR CODE [DDW9LD] (GROUND FAULT OF KICKDOWN SWITCH SYSTEM) IS DISPLAYED...11737
        ERROR CODE [DDWLLD] (GROUND FAULT OF HOLD SWITCH SYSTEM) IS DISPLAYED...11740
        ERROR CODE [DF10KA] (NO INPUT OF GEAR SHIFT LEVER SIGNAL) IS DISPLAYED...11742
        ERROR CODE [DF10KB] (INPUT OF MULTIPLE GEAR SHIFT LEVER SIGNALS) IS DISPLAYED...11744
        ERROR CODE [DGF1KX] (TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM FAILURE) IS DISPLAYED...11746
        ERROR CODE [DGR2KA] (REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM DISCONNECTION) IS DISPLAYED...11747
        ERROR CODE [DGR2KB] (GROUND FAULT OF REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED...11748
        ERROR CODE [DHT1KX] (TRANSMISSION CUT-OFF (LEFT BRAKE PRESSURE SENSOR) SIGNAL DISCONTINUITY) IS DISPLAYED...11749
        ERROR CODE [DLE2KA] (ENGINE REVOLUTION SENSOR SYSTEM DISCONTINUITY) IS DISPLAYED...11750
        ERROR CODE [DLE2LC] (ENGINE REVOLUTION SENSOR FAILURE) IS DISPLAYED...11751
        ERROR CODE [DLT3KA] (SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM DISCONTINUITY) IS DISPLAYED...11752
        ERROR CODE [DT20KB] (GROUND FAULT OF BUILT-IN INDICATOR LAMP SYSTEM OF TRANSMISSION CUT-OFF SWITCH) IS DISPLAYED...11753
        ERROR CODE [DW7BKA] (FAN PUMP REVERSE SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...11754
        ERROR CODE [DW7BKB] (FAN PUMP REVERSE SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED...11755
        ERROR CODE [DW7CKA] (SWITCH PUMP CUT-OFF RELAY DISCONTINUITY) IS DISPLAYED...11756
        ERROR CODE [DW7CKB] (SWITCH PUMP CUT-OFF RELAY GROUND FAULT) IS DISPLAYED...11757
        ERROR CODE [DX16KA] (FAN PUMP EPC SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...11758
        ERROR CODE [DX16KB] (FAN PUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...11759
        ERROR CODE [DXH1KA] (LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...11760
        ERROR CODE [DXH1KB] (LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED...11761
        ERROR CODE [DXH4KA] (1ST_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...11762
        ERROR CODE [DXH4KB] (1ST_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED...11763
        ERROR CODE [DXH5KA] (2ND_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...11764
        ERROR CODE [DXH5KB] (2ND_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED...11765
        ERROR CODE [DXH6KA] (3RD_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...11766
        ERROR CODE [DXH6KB] (3RD_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED...11767
        ERROR CODE [DXH7KA] (R_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...11768
        ERROR CODE [DXH7KB] (R_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...11769
        ERROR CODE [DXH8KA] (F_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...11770
        ERROR CODE [DXH8KB] (F_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...11771
        ERROR CODE [DXHHKA] (4TH_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED...11772
        ERROR CODE [DXHHKB] (4TH_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED...11773
        ERROR CODE [DY30MA] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE))...11774
        ERROR CODE [DY30MC] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE))...11776
        TROUBLESHOOTING CODE [TM-1] DISCONTINUITY OR HOT SHORT-CIRCUITING OF KICKDOWN SWITCH SYSTEM...11778
        TROUBLESHOOTING CODE [TM-2] HOLD SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING...11780
        TROUBLESHOOTING CODE [TM-3] TORQUE CONVERTER LOCK-UP SWITCH SYSTEM FAILURE...11782
        TROUBLESHOOTING CODE [TM-4] NEUTRALIZER SIGNAL (PARKING BRAKE SWITCH SIGNAL) SYSTEM FAILURE...11784
        TROUBLESHOOTING CODE [TM-5] EMERGENCY STEERING SWITCH (MOTOR-DRIVEN EMERGENCY STEERING OPERATION SWITCH) SIGNAL SYSTEM FAILURE...11786
        TROUBLESHOOTING CODE [TM-6] TRANSMISSION CUT-OFF SWITCH SYSTEM DISCONTINUITY OR GROUND FAULT...11788
        TROUBLESHOOTING CODE [TM-7] TRANSMISSION CUT-OFF SETTING SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING...11789
        TROUBLESHOOTING CODE [TM-8] TRANSMISSION CUT-OFF (LEFT BRAKE SENSOR) SIGNAL SHORT-CIRCUITING...11790
        TROUBLESHOOTING CODE [TM-9a] JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH SYSTEM FAILURE (DISCONTINUITY OR GROUND FAULT)...11791
        TROUBLESHOOTING CODE [TM-9b] JOYSTICK ON/OFF CHANGE OVER SWITCH SYSTEM FAILURE...11792
        TROUBLESHOOTING CODE [TM-10] FNR SWITCH MODE CHANGE OVER SWITCH SYSTEM FAILURE...11794
        TROUBLESHOOTING CODE [TM-11] STARTING SWITCH "C" (IGN_C) SIGNAL SYSTEM FAILURE...11796
        TROUBLESHOOTING CODE [TM-12] ENGINE POWER MODE SWITCH DISCONTINUITY OR GROUND FAULT...11798
        TROUBLESHOOTING CODE [TM-13] TRAVEL DAMPER ON/OFF SWITCH DISCONTINUITY OR GROUND FAULT...11799
        TROUBLESHOOTING CODE [TM-14] HYDRAULIC FAN REVERSE SWITCH SIGNAL SYSTEM HOT SHORT-CIRCUITING OR DISCONTINUITY...11800
        TROUBLESHOOTING CODE [TM-15] MOTOR-DRIVEN EMERGENCY STEERING RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING...11801
        TROUBLESHOOTING CODE [TM-16] TRAVEL DAMPER RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING...11802
        TROUBLESHOOTING CODE [TM-17] SWITCH PUMP CUT-OFF RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING...11803
        TROUBLESHOOTING CODE [TM-18] BACK LAMP RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING...11804
        TROUBLESHOOTING CODE [TM-19] NEUTRAL OUTPUT SYSTEM HOT SHORT-CIRCUITING...11805
        TROUBLESHOOTING CODE [TM-20] FECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING...11806
        TROUBLESHOOTING CODE [TM-21] RECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING...11807
        TROUBLESHOOTING CODE [TM-22] 1ST ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING...11808
        TROUBLESHOOTING CODE [TM-23] 2ND ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING...11809
        TROUBLESHOOTING CODE [TM-24] 3RD ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING...11810
        TROUBLESHOOTING CODE [TM-25] 4TH ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING...11811
        TROUBLESHOOTING CODE [TM-26] LOCK-UP ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING...11812
        TROUBLESHOOTING CODE [TM-27] FAN PUMP EPC SOLENOID SYSTEM HOT SHORT-CIRCUITING...11813
        TROUBLESHOOTING CODE [TM-28] FAN REVERSE SOLENOID SYSTEM HOT SHORT-CIRCUITING...11814
        TROUBLESHOOTING CODE [TM-29] SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM FAILURE...11815
        TROUBLESHOOTING CODE [TM-30] E.C.S.S. SOLENOID SYSTEM DISCONTINUITY OR GROUND FAULT...11816
      TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WRK MODE)...11817
        CONNECTOR TYPES AND MOUNTING LOCATIONS...11821
        CONNECTOR LAYOUT DRAWING...11830
        WORK EQUIPMENT CONTROL SYSTEM DIAGRAM...11838
        FAILURE CODE [D193KA] (DEFECTIVE JOYSTICK STEERING CUT RELAY SYSTEM (MAIN SYSTEM DISCONNECTED)) IS DISPLAYED...11841
        FAILURE CODE [D193KB] (THE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM IS GROUNDED PROPERLY) IS DISPLAYED...11842
        FAILURE CODE [DB90KK] (LOWERING WORK EQUIPMENT CONTROLLER POWER SUPPLY) IS DISPLAYED...11843
        FAILURE CODE [DB92KK] (DEFECTIVE SOLENOID ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED...11844
        FAILURE CODE [DB95KX] (DEFECTIVE 5 V ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED...11846
        FAILURE CODE [DD1ALD] (DEFECTIVE REMOTE POSITIONER UP SET SWITCH (GROUND FAULT)) IS DISPLAYED...11848
        FAILURE CODE [DD1BLD] (DEFECTIVE REMOTE POSITIONER DOWN SET SWITCH (GROUND FAULT)) IS DISPLAYED...11849
        FAILURE CODE [DFA0KM] (DEFECTIVE NEUTRAL CAUTION FOR JOYSTICK WORK EQUIPMENT LEVER) IS DISPLAYED...11850
        FAILURE CODE [DK59KA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED...11851
        FAILURE CODE [DK59KY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORT CIRCUIT)) IS DISPLAYED...11852
        FAILURE CODE [DK59L8] (DEFECTIVE LIFT ARM EPC POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED...11853
        FAILURE CODE [DK5AKA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OF MAIN) (DISCONNECTION,GROUND OF SUB)) IS DISPLAYED...11854
        FAILURE CODE [DK5AKY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED...11855
        FAILURE CODE [DK5BKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED...11856
        FAILURE CODE [DK5BKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORTED)) IS DISPLAYED...11857
        FAILURE CODE [DK5BL8] (DEFECTIVE INPUT SIGNAL FOR BUCKET EPC LEVER POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED...11858
        FAILURE CODE [DK5CKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED...11859
        FAILURE CODE [DK5CKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED...11860
        FAILURE CODE [DK5DKA] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED...11861
        FAILURE CODE [DK5DKY] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORT CIRCUIT)) IS DISPLAYED...11862
        FAILURE CODE [DK5DL8] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED...11863
        FAILURE CODE [DK5EKA] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED...11864
        FAILURE CODE [DK5EKY] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED...11865
        FAILURE CODE [DK5FKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED...11866
        FAILURE CODE [DK5FKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORTED)) IS DISPLAYED...11867
        FAILURE CODE [DK5FKM] (JOYSTICK STEERING EPC LEVER NEUTRAL SYSTEM CAUTION) IS DISPLAYED...11868
        FAILURE CODE [DK5FL8] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DEVIATION OF POSITIONAL SIGNALS OF MAIN AND SUB-CIRCUITS)) IS DISPLAYED...11869
        FAILURE CODE [DG5GKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUND FAULT OF SUB-CIRCUIT)) IS DISPLAYED...11870
        FAILURE CODE [DK5GKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT SHORT CIRCUIT)) IS DISPLAYED...11871
        FAILURE CODE [DKA0KA] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (DISCONNECTION OR GROUND FAULT)) IS DISPLAYED...11872
        FAILURE CODE [DKA0KY] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (SHORT CIRCUIT)) IS DISPLAYED...11873
        FAILURE CODE [DLE2LC] (DEFECTIVE ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED...11874
        FAILURE CODE [DLT3LC] (DEFECTIVE TRANSMISSION OUTPUT AXIS SPEED SENSOR SYSTEM (DISCONNECTED)) IS DISPLAYED...11875
        FAILURE CODE [DUM1KB] (REMOTE POSITIONER RAISE LAMP SYSTEM GROUND FAULT) IS DISPLAYED...11876
        FAILURE CODE [DUM2KB] (REMOTE POSITIONER LOWER LAMP SYSTEM GROUND FAULT) IS DISPLAYED...11877
        FAILURE CODE [DW4PKA] (DISCONNECTED LIFT ARM RAISE EPC SOLENOID SYSTEM) IS DISPLAYED...11878
        FAILURE CODE [DW4PKB] (LIFT ARM RAISE EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...11879
        FAILURE CODE [DW4QKA] (DISCONNECTED LIFT ARM LOWER EPC SOLENOID SYSTEM) IS DISPLAYED...11880
        FAILURE CODE [DW4QKB] (LIFT ARM LOWER EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...11881
        FAILURE CODE [DW4RKA] (DISCONNECTED BUCKET TILT EPC SOLENOID SYSTEM) IS DISPLAYED...11882
        FAILURE CODE [DW4RKB] (BUCKET TILT EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...11883
        FAILURE CODE [DW4SKA] (BUCKET DUMP EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED...11884
        FAILURE CODE [DW4SKB] (BUCKET DUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...11885
        FAILURE CODE [DWM1KA] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED...11886
        FAILURE CODE [DWM1KB] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...11887
        FAILURE CODE [DWN6KA] (LIFT ARM RAISE MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED...11888
        FAILURE CODE [DWN6KB] (LIFT ARM RAISE MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED...11889
        FAILURE CODE [DWN7KA] (LIFT ARM FLOATING MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED...11890
        FAILURE CODE [DWN7KB] (LIFT ARM FLOATING MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED...11891
        FAILURE CODE [DWN8KA] (BUCKET TILT MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED...11892
        FAILURE CODE [DWN8KB] (BUCKET TILT MAGNET DETENT SYSTEM FAILURE (POWER SUPPLY SYSTEM GROUND FAULT)) IS DISPLAYED...11893
        FAILURE CODE [DXHJKA] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED...11894
        FAILURE CODE [DXHJKB] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...11895
        FAILURE CODE [DXHKKA] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED...11896
        FAILURE CODE [DXHKKB] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...11897
        FAILURE CODE [DXHLKA] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED...11898
        FAILURE CODE [DXHLKB] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...11899
        FAILURE CODE [DXHMKA] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED...11900
        FAILURE CODE [DXHMKB] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED...11901
        TROUBLESHOOTING CODE [WRK-1] DEFECTIVE LIFT ARM LOCK SWITCH SYSTEM...11902
        TROUBLESHOOTING CODE [WRK-2] DEFECTIVE REMOTE POSITIONER RAISE SETTING SWITCH SYSTEM...11903
        TROUBLESHOOTING CODE [WRK-3] DEFECTIVE REMOTE POSITIONER LOWER SETTING SWITCH SYSTEM...11904
        TROUBLESHOOTING CODE [WRK-4] DEFECTIVE REMOTE POSITIONER RAISE SELECTION SWITCH SYSTEM...11906
        TROUBLESHOOTING CODE [WRK-5] DEFECTIVE REMOTE POSITIONER LOWER ON/OFF SWITCH SYSTEM...11908
        TROUBLESHOOTING CODE [WRK-6] DEFECTIVE BUCKET CYLINDER PROXIMITY SWITCH SYSTEM...11910
        TROUBLESHOOTING CODE [WRK-7] DEFECTIVE BUCKET CYLINDER FULL STROKE DETECTION SWITCH SYSTEM...11912
        TROUBLESHOOTING CODE [WRK-8] DEFECTIVE SEMI-AUTOMATIC DIGGING HARD SELECTION SWITCH SYSTEM...11913
        TROUBLESHOOTING CODE [WRK-9] DEFECTIVE SEMI-AUTOMATIC DIGGING SOFT SELECTION SWITCH SYSTEM...11914
        TROUBLESHOOTING CODE [WRK-10] DEFECTIVE JOYSTICK ON/OFF SWITCH SYSTEM...11916
        TROUBLESHOOTING CODE [WRK-11] DEFECTIVE JOYSTICK STEERING SPEED HI/LO SWITCH SYSTEM...11918
        TROUBLESHOOTING CODE [WRK-12] DEFECTIVE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM...11919
        TROUBLESHOOTING CODE [WRK-13] HOT SHORT-CIRCUITED LIFT ARM RAISE MAGNET DETENT OUTPUT SYSTEM...11920
        TROUBLESHOOTING CODE [WRK-14] HOT SHORT-CIRCUITED LIFT ARM FLOATING MAGNET DETENT OUTPUT SYSTEM...11921
        TROUBLESHOOTING CODE [WRK-15] HOT SHORT-CIRCUITED BUCKET TILT MAGNET DETENT OUTPUT SYSTEM...11922
        TROUBLESHOOTING CODE [WRK-16] HOT SHORT-CIRCUITED WORK EQUIPMENT NEUTRAL LOCK SOLENOID OUTPUT SYSTEM...11923
        TROUBLESHOOTING CODE [WRK-17] HOT SHORT-CIRCUITED LIFT ARM RAISE EPC SOLENOID SYSTEM...11924
        TROUBLESHOOTING CODE [WRK-18] HOT SHORT-CIRCUITED LIFT ARM LOWER EPC SOLENOID SYSTEM...11925
        TROUBLESHOOTING CODE [WRK-19] HOT SHORT-CIRCUITED BUCKET TILT EPC SOLENOID SYSTEM...11926
        TROUBLESHOOTING CODE [WRK-20] HOT SHORT-CIRCUITED BUCKET DUMP EPC SOLENOID SYSTEM...11927
        TROUBLESHOOTING CODE [WRK-21] HOT SHORT-CIRCUITED 3 VALVES EXTENSION EPC SOLENOID SYSTEM...11928
        TROUBLESHOOTING CODE [WRK-22] HOT SHORT-CIRCUITED 3 VALVES RETRACTION EPC SOLENOID SYSTEM...11929
        TROUBLESHOOTING CODE [WRK-23] HOT SHORT-CIRCUITED JOYSTICK STEERING RIGHT EPC SOLENOID SYSTEM...11930
        TROUBLESHOOTING CODE [WRK-24] HOT SHORT-CIRCUITED JOYSTICK STEERING LEFT EPC SOLENOID SYSTEM...11931
        TROUBLESHOOTING CODE [WRK-25] DEFECTIVE BUCKET POSITIONER, LIFT ARM KICK-OUT AND FLOATING HOLDING FUNCTION...11932
        TROUBLESHOOTING CODE [WRK-26] DEFECTIVE LIFT ARM KICK-OUT FUNCTION AND CANCELLATION...11934
        TROUBLESHOOTING CODE [WRK-27] DEFECTIVE BUCKET LEVELER FUNCTION AND CANCELLATION...11936
        TROUBLESHOOTING CODE [WRK-28] DEFECTIVE LIFT ARM FLOATING HOLDING AND CANCELLATION...11938
      TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE)...11939
        CONNECTOR TYPES AND MOUNTING LOCATIONS...11941
        CONNECTOR LAYOUT DRAWING...11950
        MONITOR SYSTEM DIAGRAM...11956
        FAILURE CODE [2F00MA] DRAGGING OF PARKING BRAKE...11960
        FAILURE CODE [2G42ZG] ACCUMULATOR OIL PRESSURE (FRONT CIRCUIT) LOW...11962
        FAILURE CODE [2G43ZG] ACCUMULATOR OIL PRESSURE (REAR BRAKE CIRCUIT) LOW...11963
        FAILURE CODE [AA1ANX] AIR CLEANER 1 CLOGGED...11964
        FAILURE CODE [AB00L6] DEFECTIVE BATTERY CHARGING CIRCUIT (ALTERNATOR TERMINAL R SIGNAL DETECTED WHEN ENGINE STOPPED...11966
        FAILURE CODE [AB00MA] DEFECTIVE BATTERY CHARGING CIRCUIT (NO ALTERNATOR TERMINAL R SIGNAL DETECTED, DETECTION FAILURE)...11967
        FAILURE CODE [B@BAZG] ENGINE OIL PRESSURE LOW...11968
        FAILURE CODE [B@BAZK] ENGINE OIL LEVEL LOW...11969
        FAILURE CODE [B@BCNS] ENGINE WATER TEMPERATURE OVERHEATING...11970
        FAILURE CODE [B@BCZK] ALARM INDICATING LOW COOLANT LEVEL...11971
        FAILURE CODE [B@HANS] HYDRAULIC OIL TEMPERATURE OVERHEATING...11972
        FAILURE CODE [B@CENS] TORQUE CONVERTER OIL TEMPERATURE OVERHEATING...11973
        FAILURE CODE [D182KZ] THE PREHEATER RELAY COIL IS DISCONNECTED OR SHIRT-CIRCUITED...11974
        FAILURE CODE [D5ZHL6] STARTING SWITCH C (IGN"C") INPUT FAILURE...11976
        FAILURE CODE [DA80L4] AUTO GREASE INPUT FAILURE...11977
        FAILURE CODE [DAF3KK] SW POWER SUPPLY (FOR OPERATION) = ON AND NSW POWER SUPPLY (FOR MEMORY) IS OFF...11978
        FAILURE CODE [DAF5KP] 5V POWER SUPPLY OUTPUT FAILURE...11980
        FAILURE CODE [DAF6KP] 24V POWER SUPPLY OUTPUT FAILURE...11982
        FAILURE CODE [DAFBKM] WRONG INFORMATION ON MODEL SELECTION...11984
        FAILURE CODE [DAFSKQ] WRONG INFORMATION ON METER DISPLAY SELECTION...11985
        FAILURE CODE [DAQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND TRANSMISSION CONTROLLER) ...11986
        FAILURE CODE [DBQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) ...11988
        FAILURE CODE [DB9SKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) ...11989
        FAILURE CODE [DD15LD] MONITOR PANEL MODE SELECTOR SWITCH 1 (PANEL SW1) INPUT ERROR...11990
        FAILURE CODE [DD16LD] MONITOR PANEL MODE SELECTOR SWITCH 1 (PANEL SW2) INPUT ERROR...11991
        FAILURE CODE [DD17LD] THE MONITOR PANEL MODE SELECTOR SWITCH 2 (PANEL SW3) INPUT CIRCUIT REMAINS CLOSED FOR MORE THAN ONE MINUTE...11992
        FAILURE CODE [DD18LD] MONITOR PANEL MODE SELECTOR SWITCH 2 (PANEL SW4) INPUT ERROR...11993
        FAILURE CODE [DD1CLD] SUB-TOTAL SWITCH FAILURE...11994
        FAILURE CODE [DDS5L6] DECREASED STEERING OIL PRESSURE...11996
        FAILURE CODE [DDY0LD] CANCEL SWITCH FAILURE...11998
        FAILURE CODE [DGE2KX] ENGINE WATER TEMPERATURE SENSOR SYSTEM FAILURE...12000
        FAILURE CODE [DGE3L6] ABNORMAL CONNECTION OF ENGINE WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM...12001
        FAILURE CODE [DGH2KX] HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM FAILURE...12002
        FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM FAILURE...12003
        FAILURE CODE [DHE4L6] ENGINE OIL PRESSURE SENSOR SYSTEM FAILURE...12004
        FAILURE CODE [DHPCKX] BOTTOM PRESSURE SENSOR FAILURE...12006
        FAILURE CODE [DHPDKX] HEAD PRESSURE SENSOR FAILURE...12008
        FAILURE CODE [DKA0KX] LIFT ARM ANGLE SENSOR FAILURE...12010
        FAILURE CODE [DV00KB] SHORT-CIRCUITED ALARM BUZZER OUTPUT SYSTEM...12011
        FAILURE CODE [DY30ME] THE EMERGENCY STEERING REMAINS ACTUATED FOR MORE THAN ONE MINUTE...12012
        TROUBLESHOOTING CODE [MON-1] THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT UP WHEN THE PARKING BRAKE SWITCH IS TURNED ON (THE PARKING BRAKE INDICATOR SWITCH CIRCUIT SUFFERS A GROUND FAULT)...12014
        TROUBLESHOOTING CODE [MON-2] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (FRONT CIRCUIT)...12016
        TROUBLESHOOTING CODE [MON-3] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (REAR CIRCUIT)...12017
        TROUBLESHOOTING CODE [MON-4] THE AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT ON...12018
        TROUBLESHOOTING CODE [MON-5] THE ENGINE HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON...12020
        TROUBLESHOOTING CODE [MON-6] THE ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT ON...12021
        TROUBLESHOOTING CODE [MON-7] THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON...12022
        TROUBLESHOOTING CODE [MON-8] THE RADIATOR WATER VOLUME CAUTION LAMP DOES NOT LIGHT ON...12023
        TROUBLESHOOTING CODE [MON-9] THE HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON...12024
        TROUBLESHOOTING CODE [MON-10] THE TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON...12025
        TROUBLESHOOTING CODE [MON-11] THE STEERING HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON...12026
        TROUBLESHOOTING CODE [MON-12] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW1)...12027
        TROUBLESHOOTING CODE [MON-13] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW2)...12028
        TROUBLESHOOTING CODE [MON-14] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW3)...12029
        TROUBLESHOOTING CODE [MON-15] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW4)...12030
        TROUBLESHOOTING CODE [MON-16] DEFECTIVE SUBTOTAL SWITCH...12031
        TROUBLESHOOTING CODE [MON-17] DEFECTIVE CANCEL SWITCH...12032
        TROUBLESHOOTING CODE [MON-18] DEFECTIVE BOTTOM PRESSURE SENSOR (HOT SHORT FAULT)...12033
        TROUBLESHOOTING CODE [MON-19] DEFECTIVE HEAD SENSOR...12034
        TROUBLESHOOTING CODE [MON-20] THE ALARM BUZZER DOES NOT SOUND OR STOP (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN BUZZER OUTPUT SYSTEM)...12035
      TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)...12037
        H-1 THE MACHINE DOES NOT START...12038
        H-2 THE LOCK-UP CLUTCH IS NOT RELEASED (THE ENGINE STOPS) (WHEN THE LOCK-UP CLUTCH IS PROVIDED)...12040
        H-3...12041
          a. THE TRAVEL SPEED IS SLOW, THE THRUSTING FORCE IS WEAK, THE UPHILL TRAVELING POWER IS WEAK, AND THE GEAR IS NOT SHIFTED...12041
          b. THE TORQUE CONVERTER LOCK-UP CLUTCH IS NOT LET IN (IF THE LOCK-UP CLUTCH IS EQUIPPED)...12043
        H-4 SHOCKS ARE LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR...12044
        H-5 TIME LAG IS LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR...12046
        H-6 THE TORQUE CONVERTER OIL TEMPERATURE IS HIGH...12048
        H-7 THE STEERING WHEEL DOES NOT TURN...12049
        H-8 THE STEERING WHEEL IS HEAVY...12050
        H-9 THE STEERING WHEEL FLUCTUATES OR IS STRONGLY SHOCKED ...12051
        H-10 THE MACHINE STEERS TO ONE SIDE WHEN STAVELING...12051
        H-11 THE RIGHT AND LEFT SWING RADII ARE DIFFERENT...12051
        H-12 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL...12052
        H-13 THE BRAKE IS NOT RELEASED OR IS DRAGGED...12053
        H-14 THE BRAKE IS NOT RELEASED OR DRAGGED...12054
        H-15 THE LIFT ARM DOES NOT RISE...12055
        H-16 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT...12056
        H-17 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT...12057
        H-18 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR)...12057
        H-19 HYDRAULIC DRIFTS OF THE BOOM OCCUR OFTEN...12057
        H-20 THE LIFT ARM WOBBLES DURING OPERATION...12057
        H-21 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "RAISE", THE LIFT ARM FALLS TEMPORARILY...12058
        H-22 THE BUCKET DOES NOT TILT BACK...12059
        H-23 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT...12060
        H-24 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILTING-BACK...12061
        H-25 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET...12061
        H-26 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN...12061
        H-27 THE BUCKET WOBBLES DURING TRAVEL CARGO (THE WORK EQUIPMENT VALVE IS SET TO "HOLD")...12062
        H-28 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "TILT", THE BUCKET FALLS TEMPORARILY...12062
        H-29 THE CONTROL LEVERS OF LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY...12063
        H-30 E.C.S.S. DOES NOT WORK, AND THERE IS PITCING AND BOUNCING...12064
      TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...12065
        CONNECTOR TYPES AND MOUNTING LOCATIONS...12067
        CONNECTOR LAYOUT DRAWING...12076
        ELECTRICAL SYSTEM DIAGRAM...12082
        TROUBLESHOOTING CODE [E-1-a] (THE ENGINE DOES NOT START. (STARTING SYSTEM))...12084
        TROUBLESHOOTING CODE [E-1-b] (THE ENGINE DOES NOT START. (ENGINE STOP SOLENOID SYSTEM))...12088
        TROUBLESHOOTING CODE [E-2] (THE ENGINE DOES NOT STOP)...12090
        TROUBLESHOOTING CODE [E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT)...12092
        TROUBLESHOOTING CODE [E-4] (THE ENGINE POWER MODES CANNOT BE SELECTED)...12094
        TROUBLESHOOTING CODE [E-5] (THE FRONT WIPER DOES NOT FUNCTION)...12096
        TROUBLESHOOTING CODE [E-6] (THE REAR WIPER DOES NOT FUNCTION)...12099
        TROUBLESHOOTING CODE [E-7] (THE SIDE WIPER DOES NOT FUNCTION (IF EQUIPPED))...12100
        TROUBLESHOOTING CODE [E-8] (THE WIND WASHER DOES NOT FUNCTION)...12101
        TROUBLESHOOTING CODE [E-9] (THE HEADLAMP (LO BEAM) DOES NOT LIGHT ON)...12104
        TROUBLESHOOTING CODE [E-10] (THE HEADLAMP (HI BEAM) DOES NOT FUNCTION)...12107
        TROUBLESHOOTING CODE [E-11] (THE CLEARANCE LAMP DOES NOT LIGHT ON (SMALL LAMP))...12109
        TROUBLESHOOTING CODE [E-12] (THE TURN SIGNAL DOES NOT BLINK)...12110
        TROUBLESHOOTING CODE [E-13] (THE HORN DOES NOT SOUND)...12112
        TROUBLESHOOTING CODE [E-14] (THE AIR CONDITIONER DOES NOT WORK OR DOES NOT STOP)...12114
      TROUBLESHOOTING OF ENGINE (S MODE)...12117
        METHOD OF USING TROUBLESHOOTING CHARTS...12118
        S-1 STARTING PREFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...12122
        S-2 ENGINE DOES NOT START...12123
          (1) ENGINE DOES NOT TURN...12123
          (2) ENGINE TURN BUT NO EXHAUST SMOKE COMES OUT (FUEL IS BEING INJECTED)...12124
          (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...12125
        S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...12126
        S-4 ENGINE STOPS DURING OPERATIONS...12127
        S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...12128
        S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...12129
        S-7 EXHAUST SMOKE IS BLACK (INCOMPLATE COMBUSTION)...12130
        S-8 OIL CONSUMPTION IS ESCESSIVE (OR EXHAUST SMOKE IS BLUE)...12131
        S-9 OIL BECOMES CONTAMINATED QUICKLY...12132
        S-10 FUEL CONSUMPTION IS EXCESSIVE...12133
        S-11 OIL IS IN COOLING COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN...12134
        S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...12135
        S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...12136
        S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...12137
        S-15 ABNORMAL NOISE IS MADE...12138
        S-16 VIBRATION IS EXCESSIVE...12139
  30 DISASSEMBLY AND ASSEMBLY...12141
    METHOD OF USING MANUAL...12142
    PRECAUTIONS WHEN CARRYING OUT OPERATION...12144
    SPECIAL TOOL LIST...12147
    REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY...12159
    REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY...12163
    REMOVAL AND INSTALLATION OF RADIATOR AND FAN MOTOR ASSEMBLY...12168
    REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY...12170
    REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP...12170
    REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY...12173
    REMOVAL AND INSTALLATION OF FAN AND MOTOR ASSEMBLY...12175
    REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY...12176
    REMOVAL AND INSTALLATION OF PARKING BRAKE DISC PLATE...12178
    REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...12181
    DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY...12185
    DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH PACK ASSEMBLY...12197
    DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY...12212
    DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (STANDARD SPECIFICATION)...12220
    DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (LOCK-UP SPECIFICATION)...12224
    REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY...12230
    REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY...12233
    DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY...12234
    DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY...12242
    REMOVAL AND INSTALLATION OF CENTER HINGE PIN...12261
    REMOVAL AND INSTALLATION OF CAB ASSEMBLY...12268
    REMOVAL AND INSTALLATION OF CAB AND FLOOR FRAME ASSEMBLY...12269
    REMOVAL AND INSTALLATION OF TRANSMISSION OF OPERATOR'S CAB GLASS (STUCK GLASS)...12272
    REMOVAL AND INSTALLATION OF TRANSMISSION, WORK EQUIPMENT, AND PPC PUMP ASSEMBLY...12280
    REMOVAL AND INSTALLATION OF STEERING, SWITCHING, AND FAN PUMP ASSEMBLY...12281
    REMOVAL AND INSTALLATION OF STEERING DEMAND VALVE ASSEMBLY...12282
    REMOVAL AND INSTALLATION OF STEERING VALVE OIL SEAL...12283
    REMOVAL AND INSTALLATION OF E.C.S.S. VALVE ASSEMBLY...12285
    REMOVAL AND INSTALLATION OF WORK EQUIPMENT VALVE ASSEMBLY...12286
    DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY (STEERING, LIFT, AND BUCKET CYLINDER ASSEMBLY)...12288
    REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY...12296
    REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY...12298
    REMOVAL AND INSTALLATION OF COUNTER WEIGHT...12302
    REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY...12303
    REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY...12306
    DISASSEMBLY, ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY...12307
  90 OTHERS...12317
    POWER TRAIN OIL CIRCUIT DIAGRAM (WITHOUT TORQUE CONVERTER LOCKUP CLUTCH)...12319
    POWER TRAIN OIL CIRCUIT DIAGRAM (WITH TORQUE CONVERTER LOCKUP CLUTCH)...12321
    BRAKE OIL CIRCUIT DIAGRAM...12323
    WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...12325
    WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (FOR ELECTRIC WORK EQUIPMENT LEVER)...12326
    ELECTRICAL CIRCUIT DIAGRAM...12327
      1/8 (1/4)...12327
      1/8 (2/4)...12328
      1/8 (3/4)...12329
      1/8 (4/4)...12330
      2/8 (1/4)...12331
      2/8 (2/4)...12332
      2/8 (3/4)...12333
      2/8 (4/4)...12334
      3/8...12335
      4/8...12336
      5/8...12337
      6/8...12338
      7/8...12339
      8/8...12340
SEBMU4230106 - Wheel Loader WA380-1 Shop Manual...12341
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  sebmu4230106  a3 tek..pdf...0
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    ...13412
    ...13413
    ...13414
    ...13415
    ...13416
SEN00769-03 - Wheel Loader WA380-6 Shop Manual...13417
  COVER...13417
  00 Index and foreword...13419
    Index...13419
      Composition of shop manual...13420
      Table of contents...13422
    Foreword and general information...13435
      Safety notice...13436
      How to read the shop manual...13441
      Explanation of terms for maintenance standard...13443
      Handling electric equipment and hydraulic component...13445
      How to read electric wire code...13457
      Precautions when carrying out operation...13460
      Method of disassembling and connecting push-pull type coupler...13463
      Standard tightening torque table...13466
      Conversion table...13470
  01 Specification...13477
    Specification and technical data...13477
      Specification and technical data...13479
        Specification dimension drawing...13479
        Specifications...13480
        Weight table...13484
        Table of fuel, coolant and lubricants...13486
  10 Structure, function and maintenance standard...13489
    Engine and cooling system...13489
      Engine and cooling system...13490
        Engine mount and transmission mount...13490
        Cooling system...13491
        Cooling fan pump...13492
        Cooling fan motor...13500
    Power train...13507
      Power train...13509
        Power train...13509
        Power train system diagram...13510
        Drive shaft...13512
        Power train piping diagram...13513
        Torque converter...13514
        Transmission...13522
        Flow control valve...13539
        Valve assembly...13540
        ECMV...13541
        Main relief valve and torque converter relief valve...13548
        Axle...13550
        Front axle...13550
        Rear axle...13551
        Differential...13552
        Front differential...13552
        Rear differential...13553
        Limited slip differential...13557
        Final drive...13564
    Steering system...13569
      Steering system...13570
        Steering piping diagram...13570
        Steering column...13571
        Steering pump...13572
        Steering valve...13583
        Orbit-roll valve...13598
        Stop valve...13602
        Steering relief valve...13603
        Steering cylinder...13604
        Emergency steering motor...13606
        Emergency steering pump...13607
    Brake system...13609
      Brake system...13610
        Brake piping diagram...13610
        Charge valve...13611
        Brake valve...13618
        Accumulator (for brake)...13623
        Brake...13624
        Parking brake control...13629
        Parking brake...13630
        Parking brake solenoid valve...13632
        Emergency parking brake release valve...13634
    Undercarriage and frame...13637
      Undercarriage and frame...13638
        Axle mount and center hinge pin...13638
        Tires...13642
    Hydraulic system, Part 1...13645
      Hydraulic system, Part 1...13646
        Hydraulic piping diagram...13646
        Work equipment control lever linkage...13649
        Hydraulic tank...13650
        Breather...13651
        Power train pump...13652
        Work equipment pump...13653
        Work equipment control valve...13664
        CLSS...13678
        Outline of CLSS...13678
        Basic principle...13679
        Each function and operation of each valve...13682
        Hydraulic circuit diagram and names of valves...13682
        Area ratio of pressure compensation valve...13692
        Lift arm regeneration circuit...13694
        Variable lift check valve...13696
        ECSS control valve...13697
        Restriction on lift arm raise stroke...13698
        Accumulator charge valve...13700
    Hydraulic system, Part 2...13705
      Hydraulic system, Part 2...13706
        PPC valve...13706
        Stabilizer valve...13712
        Accumulator (for PPC circuit)...13717
        Accumulator (for ECSS)...13718
    Work equipment...13721
      Work equipment...13722
        Work equipment linkage...13722
        Bucket...13724
        Bucket positioner and boom kick-out...13725
        Work equipment cylinder...13731
    Cab and its attachments...13733
      Cab and its attachments...13735
        Cab...13735
        Air conditioner...13736
        Air conditioner piping diagram...13736
        Air conditioner unit...13739
        Blower and intake unit...13741
        Compressor...13742
        Condenser...13743
        Receiver...13744
        Air conditioner panel...13746
    Electrical system, Part 1...13749
      Electrical system, Part 1...13750
        Machine monitor system...13750
        System circuit diagram...13752
        Machine monitor...13755
        List of items displayed on monitor...13756
        Machine monitor operation switch...13760
        Setting of machine monitor...13761
        Character display...13762
        Operator mode functions...13763
        Service mode functions...13766
        Input and output signals...13771
    Electrical system, Part 2...13777
      Electrical system, Part 2...13778
        Electrical system (Transmission controller system)...13778
        Transmission controller...13810
    Electrical system, Part 3...13813
      Electrical system, Part 3...13813
        Electric transmission control...13814
        Kickdown switch and hold switch...13818
        KOMTRAX terminal system...13820
        Engine starting circuit...13822
        Engine stopping circuit...13824
        Preheating circuit...13825
        Engine power mode selector circuit...13826
        Engine output derating function...13827
        Parking brake circuit...13828
        Automatic warm-up function...13827
        Sensor...13830
  20 Standard value table...13839
    Standard service value table...13839
      Standard service value table...13840
        Standard service value table for engine...13840
        Standard service value table for chassis...13841
  30 Testing and adjusting...13849
    Testing and adjusting, Part 1...13849
      Testing and adjusting, Part 1...13851
        Tools for testing, adjusting, and troubleshooting...13851
        Measuring engine speed...13854
        Measuring exhaust gas color...13856
        Adjusting valve clearance...13858
        Measuring compression pressure...13860
        Measuring blow-by pressure...13863
        Measuring engine oil pressure...13864
        Measuring intake air (boost) pressure...13865
        Handling fuel system equipment...13866
        Releasing residual pressure in fuel system...13866
        Measuring fuel pressure...13867
        Measuring fuel return rate and leakage...13869
        Bleeding air from fuel circuit...13872
        Testing leakage in fuel system...13874
        Handling reduced cylinder mode operation...13875
        Handling no-injection cranking operation...13875
        Handling controller voltage circuit...13876
        Testing and adjusting air conditioner compressor belt tension...13877
        Adjusting transmission speed sensor...13878
        Measuring directional lever...13879
        Measuring and adjusting power train oil pressure...13880
        Procedure for flushing torque converter and transmission hydraulic circuit...13895
        Method of moving machine when transmission valve is broken...13896
        Testing and adjusting steering stop valve...13898
        Testing and adjusting steering wheel...13900
        Testing steering oil pressure...13902
        Bleeding air from steering circuit...13905
    Testing and adjusting, Part 2...13907
      Testing and adjusting, Part 2...13909
        Testing hydraulic drive fan...13909
        Bleeding air from hydraulic drive fan circuit...13911
        Measuring brake pedal...13913
        Measuring brake performance...13914
        Testing and adjusting accumulator charge pressure...13915
        Testing wheel brake oil pressure...13916
        Measuring wear of wheel brake disc...13918
        Bleeding air from wheel brakecircuit...13919
        Releasing residual pressure in brake accumulator circuit...13920
        Testing parking brake performance...13921
        Measuring parking brake oil pressure...13922
        Testing wear of parking brake disc...13924
        Method of releasing parking brake manually...13925
        Measuring and adjusting work equipment control lever...13926
        Measuring and adjusting work equipment PPC oil pressure...13927
        Measuring and adjusting work equipment oil pressure...13930
        Bleeding air from work equipment circuit...13934
        Releasing residual pressure in work equipment circuit...13935
        Testing and adjusting bucket positioner...13936
        Testing and adjusting boom kickout...13938
        Checking proximity switch operation pilot lamp...13939
        Procedure for testing diodes...13940
        Preparation work for troubleshooting for electric system...13941
        How to start operation of KOMTRAX terminal...13946
        Lamp display of KOMTRAX terminal...13951
        Adjusting machine monitor...13954
        Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor...13955
    Testing and adjusting, Part 3...13959
      Testing and adjusting, Part 3...13960
        Special functions of machine monitor (EMMS)...13960
        Pm-click inspection table...14019
  40 Troubleshooting...14023
    General information on troubleshooting...14023
      General information on troubleshooting...14024
        Points to remember when troubleshooting...14024
        Sequence of events in troubleshooting...14025
        Testing before troubleshooting...14026
        Classification and procedures of troubleshooting...14027
        Connection table for connector pin numbers...14030
        T-branch box and T-branch adapter table...14053
    Troubleshooting by failure code (Display of code), Part 1...14057
      Troubleshooting by failure code (Display of code), Part 1...14059
        Failure codes list...14059
        Before carrying out troubleshooting for electrical system...14066
        Information contained troubleshooting table...14069
        Failure code [1500L0] (TORQFLOW transmission: Double meshing)...14071
        Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)...14072
        Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)...14074
        Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)...14076
        Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)...14078
        Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)...14080
        Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)...14082
        Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)...14084
        Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)...14086
        Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)...14088
        Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)...14090
        Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)...14092
        Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)...14094
        Failure code [2F00MA] (Parking brake: Malfunction)...14096
    Troubleshooting by failure code (Display of code), Part 2...14099
      Troubleshooting by failure code (Display of code), Part 2...14102
        Failure code [2G43ZG] (Accumulator: Low oil pressure)...14102
        Failure code [AA1ANX] (Air cleaner: Clogging)...14104
        Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)...14106
        Failure code [AB00MA] (Alternator: Malfunction)...14108
        Failure code [B@BAZG] (Rotation derating by low engine oil pressure)...14110
        Failure code [B@BAZK] (Engine oil: Low level)...14111
        Failure code [B@BCNS] (Coolant: Overheating)...14112
        Failure code [B@BCZK] (Coolant: Low level)...14114
        Failure code [B@C7NS] (Brake oil: Overheating)...14116
        Failure code [b@CENS] (Torque converter oil: Overheating)...14118
        Failure code [B@CENS] (Torque converter oil: Overheating)...14120
        Failure code [B@HANS] (Hydraulic oil: Overheating)...14122
        Failure code [CA111] (Abnormality in engine controller)...14124
        Failure code [CA115] (Engine Ne or Bkup speed sensor error)...14125
        Failure code [CA122] (Charge pressure sensor high error)...14126
        Failure code [CA123] (Charge pressure sensor low error)...14128
        Failure code [CA131] (Throttle sensor high error)...14130
        Failure code [CA132] (Throttle sensor low error)...14132
        Failure code [CA144] (Coolant sensor high error)...14134
        Failure code [CA145] (Coolant sensor low error)...14136
        Failure code [CA153] (Charge temperature sensor high error)...14138
        Failure code [CA154] (Charge temperature sensor low error)...14140
        Failure code [CA155] (Derating of speed by abnormally high charge temperature)...14142
        Failure code [CA187] (Sensor power supply 2 low error)...14144
        Failure code [CA221] (Atmospheric pressure sensor high error)...14146
        Failure code [CA222] (Atmospheric sensor low error)...14148
        Failure code [CA227] (Sensor power supply 2 high error)...14150
    Troubleshooting by failure code (Display of code), Part 3...14153
      Troubleshooting by failure code (Display of code), Part 3...14155
        Failure code [CA234] (Engine overspeed)...14155
        Failure code [CA238] (Ne speed sensor power supply error)...14156
        Failure code [CA271] (PCV1 Short circuit)...14157
        Failure code [CA272] (PCV1 Disconnection)...14158
        Failure code [CA322] (Injector #1 (L/B #1) open/short error)...14160
        Failure code [CA323] (Injector #5 (L/B #5) open/short error)...14162
        Failure code [CA324] (Injector #3 (L/B #3) open/short error)...14164
        Failure code [CA325] (Injector #6 (L/B #6) open/short error)...14166
        Failure code [CA331] (Injector #2 (L/B #2) open/short error)...14168
        Failure code [CA332] (Injector #4 (L/B #4) open/short error)...14170
        Failure code [CA342] (Calibration code inconsistency)...14172
        Failure code [CA351] (Injectors drive circuit error)...14173
        Failure code [CA352] (Sensor power supply 1 low error)...14175
        Failure code [CA386] (Sensor power supply 1 high error)...14177
        Failure code [CA428] (Abnormally high level in water sensor)...14178
        Failure code [CA429] (Abnormally low level in water sensor)...14180
        Failure code [CA431] (Idle validation switch error)...14182
        Failure code [CA432] (Idle validation action error)...14184
        Failure code [CA435] (Engine oil pressure switch error)...14186
        Failure code [CA441] (Battery voltage low error)...14187
        Failure code [CA442] (Battery voltage high error)...14190
        Failure code [CA449] Common rail pressure high error 2...14192
        Failure code [CA451] (Common rail pressure sensor high error)...14193
        Failure code [CA452] (Common rail pressure sensor low error)...14195
        Failure code [CA488] (Derating of torque by abnormally high charge temperature)...14197
        Failure code [CA553] (Common rail pressure high error 1)...14198
        Failure code [CA559] (Supply pump pressure very low error)...14199
        Failure code [CA689] (Engine Ne speed sensor error)...14200
        Failure code [CA731] (Engine Bkup speed sensor phase error)...14202
        Failure code [CA757] (All continuous data lost error)...14203
        Failure code [CA778] (Engine Bkup speed sensor error)...14206
        Failure code [CA1117] (Partial engine controller data loss error)...14208
        Failure code [CA1633] (KOMNET datalink timeout error)...14211
    Troubleshooting by failure code (Display of code), Part 4...14215
      Troubleshooting by failure code (Display of code), Part 4...14217
      Failure code [CA2185] (Throttle sensor supply voltage high error)...14217
      Failure code [CA2186] (Throttle sensor power supply low error)...14218
      Failure code [CA2249] (Supply pump pressure very low error 2)...14219
      Failure code [CA2311] (Abnormality in IMV solenoid)...14220
      Failure code [CA2555] (Intake heater relay disconnection error)...14222
      Failure code [CA2556] (Intake heater relay short circuit error)...14224
      Failure code [D150KA] (Emergency steering relay: Disconnection)...14226
      Failure code [D150KB] (Emergency steering relay: Short circuit)...14228
      Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)...14230
      Failure code [D160KA] (Backup lamp relay: Disconnection)...14232
      Failure code [D160KB] (Backup lamp relay: Short circuit)...14234
      Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)...14236
      Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)...14238
      Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)...14240
      Failure code [D192KA] (ECSS solenoid: Disconnection)...14242
      Failure code [D192KB] (ECSS solenoid: Short circuit)...14243
      Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)...14244
      Failure code [D5ZHKA] (Terminal C signal: Disconnection)...14245
      Failure code [D5ZHKB] (Terminal C signal: Short circuit)...14249
      Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)...14253
      Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)...14256
      Failure code [DAF3KK] (Machine monitor: Low source voltage (input))...14258
      Failure code [DAF5KP] (Machine monitor: Low output voltage)...14260
      Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))...14263
      Failure code [DAQ0KK] (Transmission controller: Low source voltage)...14265
      Failure code [DAQ0KT] (Transmission controller: Abnormality incontroller)...14267
      Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))...14268
      Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)...14270
    Troubleshooting by failure code (Display of code), Part 5...14273
      Troubleshooting by failure code (Display of code), Part 5...14275
        Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system))...14275
        Failure code [DAQRMA] (Transmission controller option setting:Malfunction)...14277
        Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)...14278
        Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)...14281
        Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system))...14282
        Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)...14284
        Failure code [DD15LD] switch (Panel switch 1): Switch is kept pressed for long time...14286
        Failure code [DD16LD] switch (Panel switch 2): Switch is kept pressed for long time...14288
        Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time...14290
        Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time...14292
        Failure code [DD1CLD] Load meter subtotal switch: Switch is keptpressed for long time...14294
        Failure code [DD1FLD] Load meter mode selector switch (A/B): Switchis kept pressed for long time...14296
        Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time...14298
        Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)...14300
        Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)...14302
        Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)...14304
        Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)...14306
    Troubleshooting by failure code (Display of code), Part 6...14311
      Troubleshooting by failure code (Display of code), Part 6...14314
        Failure code [DDK3KA] (Right FNR switch: Disconnection)...14314
        Failure code [DDK6KA] (FNR lever switch: Disconnection)...14317
        Failure code [DDK6KB] (FNR lever switch: Short circuit)...14320
        Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)...14322
        Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)...14324
        Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)...14326
        Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)...14328
        Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)...14330
        Failure code [DF10KA] (Transmission shift lever switch: Disconnected)...14332
        Failure code [DF10KB] (Transmission shift lever switch: Short circuit)...14336
        Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)...14338
        Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)...14340
        Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)...14342
        Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)...14344
        Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)...14346
        Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)...14348
    Troubleshooting by failure code (Display of code), Part 7...14351
      Troubleshooting by failure code (Display of code), Part 7...14352
      Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)...14352
      Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)...14354
      Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)...14356
      Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)...14358
      Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)...14360
    Troubleshooting by failure code (Display of code), Part 8...14363
      Troubleshooting by failure code (Display of code), Part 8...14364
      Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)...14364
      Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)...14366
      Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)...14368
      Failure code [DV00KB] (Alarm buzzer: Short circuit)...14370
    Troubleshooting by failure code (Display of code), Part 9...14373
      Troubleshooting by failure code (Display of code), Part 9...14374
        Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)...14374
        Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)...14375
        Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)...14376
        Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)...14378
        Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)...14379
        Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)...14380
        Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)...14382
        Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)...14384
        Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)...14386
        Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)...14388
        Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)...14390
    Troubleshooting by failure code (Display of code), Part 10...14393
      Troubleshooting by failure code (Display of code), Part 10...14396
        Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)...14396
        Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)...14398
        Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)...14400
        Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)...14402
        Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)...14404
        Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)...14406
        Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)...14408
        Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)...14410
        Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)...14412
        Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)...14414
        Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)...14416
        Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)...14418
        Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)...14420
        Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)...14422
        Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)...14424
        Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)...14426
    Troubleshooting of electrical system (E-mode)...14429
      Troubleshooting of electrical system (E-mode)...14431
        Before carrying out troubleshooting for electrical system...14431
        Information in troubleshooting table...14434
        E-1 Engine does not start...14435
        E-2 Wiper does not operate...14442
        E-3 Windshield washer does not operate...14446
        E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off...14449
        E-5 Working lamp does not light up or go off...14457
        E-6 Turn signal lamp and hazard lamp do not light up or go off...14462
        E-7 Brake lamp does not light or it keeps lighting up...14468
        E-8 Backup lamp does not light or it keeps lighting up...14470
        E-9 Backup buzzer does not sound or it keeps sounding...14472
        E-10 Horn does not sound or it keeps sounding...14474
        E-11 Alarm buzzer does not sound or it keeps sounding...14476
        E-12 Air conditioner does not operate or stop...14478
        E-13 The KOMTRAX system does not work properly...14481
    Troubleshooting of hydraulic and mechanical system (H-mode)...14485
      Troubleshooting of hydraulic and mechanical system (H-mode)...14487
        Method of using troubleshooting chart...14487
        Table of failure modes and causes...14490
        H-1 The machine does not start...14494
        H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]...14496
        H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]...14497
        H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted...14498
        H-5 Shocks are large at the times of starting and shifting gear...14500
        H-6 Time lag is large at the times of starting and shifting gear...14502
        H-7 The torque converter oil temperature is high...14504
        H-8 Steering does not turn...14505
        H-9 Steering does not turn [Machine with joystick steering (if equipped)]...14506
        H-10 Steering response is low...14507
        H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]...14508
        H-12 Steering is heavy...14509
        H-13 When machine turns, it shakes or makes large shocks...14510
        H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]...14511
        H-15 The wheel brake does not work or does not work well...14512
        H-16 The wheel brake is not released or it drags...14513
        H-17 The parking brake does not work or does not work well...14514
        H-18 The parking brake is not released or it drags (including emergency release system)...14515
        H-19 Lift arm does not rise...14516
        H-20 Lift arm speed is low or rising force of lift arm is insufficient...14517
        H-21 When rising, the lift arm comes to move slowly at specific height...14518
        H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)...14518
        H-23 Hydraulic drifts of the lift arm is large...14518
        H-24 The lift arm wobbles during operation...14518
        H-25 Bucket does not tilt back...14519
        H-26 Bucket speed is low or tilting back force is insufficient...14520
        H-27 The bucket comes to operate slowly in the midst of tilting-back...14521
        H-28 The bucket cylinder cannot hold down the bucket...14521
        H-29 Hydraulic drifts of the bucket is large...14521
        H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”)...14521
        H-31 Lift arm and bucket control levers do not move smoothly and are heavy...14522
        H-32 During operation of the machine, engine speed lowers remarkably or engine stalls...14523
        H-33 Large shock is made when work equipment starts and stops...14523
        H-34 When work equipment circuit is relieved singly, other work equipment moves...14523
        H-35 ECSS does not operate, and pitching, bouncing occur...14524
    Troubleshooting of engine (S-mode)...14527
      Troubleshooting of engine (S-mode)...14529
        Method of using troubleshooting chart...14529
        S-1 Engine does not start easily...14532
        S-2 Engine does not start...14533
        S-3 Engine does not pick up smoothly...14536
        S-4 Engine stops during operations...14537
        S-5 Engine does not rotate smoothly...14538
        S-6 Engine lacks output (or lacks power)...14539
        S-7 Exhaust smoke is black (Incomplete combustion)...14540
        S-8 Oil consumption is excessive (or exhaust smoke is blue)...14541
        S-9 Engine oil becomes contaminated quickly...14542
        S-10 Fuel consumption is excessive...14543
        S-11 Coolant contains oil (blows back or reduces)...14544
        S-12 Oil pressure drops...14545
        S-13 Oil level rises (Water, fuel in oil)...14546
        S-14 Coolant temperature rises too high (Overheating)...14547
        S-15 Abnormal noise is made...14548
        S-16 Vibration is excessive...14549
  50 Disassembly and assembly...14551
    General information on disassembly and assembly...14551
      General information on disassembly and assembly...14552
        How to read this manual...14552
        Coating materials list...14554
        Special tools list...14557
    Engine and cooling system...14561
      Engine and cooling system...14562
        Removal and installation of fuel supply pump assembly...14562
        Removal and installation of fuel injector assembly...14564
        Removal and installation of cylinder head assembly...14569
        Removal and installation of engine hood...14578
        Removal and installation of radiator assembly...14580
        Removal and installation of air aftercooler...14582
        Removal and installation of hydraulic oil cooler assembly...14584
        Removal and installation of engine assembly...14586
        Removal and installation of cooling fan and fan motor assembly...14591
        Removal and installation of fuel tank assembly...14594
    Power train...14597
      Power train...14598
      Removal and installation of torque converter and transmission assembly...14598
      Disassembly and assembly of torque converter assembly (Standard specification)...14604
      Disassembly and assembly of torque converter assembly (Lockup specification)...14608
      Disassembly and assembly of transmission assembly...14614
      Disassembly and assembly of transmission clutch pack assembly...14629
      Disassembly and assembly of parking brake assembly...14645
      Removal and installation of front axle assembly...14650
      Removal and installation of rear axle assembly...14652
      Disassembly and assembly of axle housing...14655
      Disassembly and assembly of differential assembly...14664
    Steering system...14679
      Steering system...14680
        Removal and installation of steering demand valve assembly...14680
    Brake system...14683
      Brake system...14684
      Removal and installation of parking brake discs and plates...14684
    Undercarriage and frame...14687
      Undercarriage and frame...14688
      Removal and installation of center hinge pin...14688
      Removal and installation of counterweight...14696
    Hydraulic system...14699
      Hydraulic system...14700
      Removal and installation of work equipment control valve assembly...14700
      Removal and installation of power train pump and work equipment pump assembly...14702
      Removal and installation of steering pump and cooling fan pump assembly...14703
      Removal and installation of hydraulic tank assembly...14704
    Work equipment...14709
      Work equipment...14710
      Removal and installation of work equipment assembly...14710
      Disassembly and assembly of hydraulic cylinder assembly...14714
    Cab and its attachments...14723
      Cab and its attachments...14724
        Removal and installation of operator's cab and floor frame assembly...14724
        Removal and installation of operator's cab glass (stuck glass)...14727
        Removal and installation of air conditioner unit assembly...14735
    Electrical system...14739
      Electrical system...14740
      Removal and installation of engine controller assembly...14740
  90 Diagrams and drawings...14743
    Hydraulic diagrams and drawings...14743
      Hydraulic diagrams and drawings...14744
        Power train hydraulic circuit diagram...14744
        Hydraulic circuit diagram...14747
    Electrical diagrams and drawings...14750
      Electrical diagrams and drawings...14752
        Electrical circuit diagram (1/2)...14752
        Electrical circuit diagram (2/2)...14753
        Connector arrangement diagram...14754
SEN05650-03 - Wheel Loader WA380-7 Shop Manual...14757
  COVER...14757
  00 Index and foreword ...14759
    Index ...14760
    Foreword, safety and general information ...14776
      Important safety notice ...14776
      How to read the shop manual ...14783
      Explanation of terms for maintenance standard ...14785
      Handling equipment of fuel system devices ...14787
      Handling of intake system parts ...14788
      Handling of hydraulic equipment ...14789
      Method of disconnecting and connecting of push-pull type coupler ...14791
      Handling of electrical equipment ...14794
      How to read electric wire code ...14802
      Precautions when performing operation ...14805
      Practical use of KOMTRAX ...14809
      Standard tightening torque table ...14810
      List of abbreviation ...14814
      Conversion table ...14819
  01 Specification ...14825
    Table of contents ...14826
    Specifications ...14827
      Specification drawing ...14827
      Specification ...14829
      Weight table ...14835
      Table of fuel, coolant and lubricants ...14837
  10 Structure and function ...14839
    Table of contents ...14840
    Engine and cooling system ...14842
      Engine related parts ...14842
      KVGT ...14844
      EGR system piping drawing ...14851
      EGR system circuit diagram ...14853
      EGR valve ...14855
      EGR cooler ...14857
      KCCV layout drawing ...14858
      KCCV ventilator ...14860
      KDPF ...14862
      Cooling system ...14866
      Cooling fan pump ...14869
      Cooling fan motor ...14878
    Power train ...14886
      Power train system ...14886
      Drive shaft ...14889
      Power train piping drawing ...14890
      Transmission control ...14891
      Torque converter ...14893
      Transmission ...14898
      Transmission control valve ...14917
      Forward and reverse clutch ECMV and gear speed clutch ECMV ...14920
      Lockup clutch ECMV ...14927
      Main relief and torque converter relief valve ...14931
      Axle ...14933
      Differential ...14935
      Limited slip differential ...14939
      Final drive ...14943
    Steering system ...14945
      Layout of steering devices ...14945
      Steering column ...14946
      Steering pump ...14947
      Steering valve ...14959
      Orbit-roll valve ...14973
      Stop valve ...14979
      Emergency steering motor ...14980
      Emergency steering pump ...14981
    Brake system ...14982
      Layout of brake parts ...14982
      Charge valve ...14984
      Brake valve ...14990
      Accumulator (for brake) ...14994
      Brake ...14995
      Parking brake control ...14998
      Parking brake ...14999
      Parking brake solenoid valve ...15000
      Parking brake emergency release valve ...15003
    Undercarriage and frame ...15004
      Axle mount and center hinge pin ...15004
      Tire ...15005
    Hydraulic system ...15007
      Hydraulic component layout ...15007
      Work equipment control ...15009
      Hydraulic tank ...15011
      Double type gear pump ...15013
      Work equipment pump ...15014
      Control valve ...15026
      CLSS ...15036
      Hydraulic circuit diagram and name of valves ...15040
      Accumulator charge valve ...15055
      Stabilizer valve ...15059
      Work equipment lock solenoid valve ...15064
      Accumulator (for PPC circuit) ...15065
      Accumulator (for ECSS) ...15066
    Work equipment ...15067
      Work equipment linkage ...15067
      Bucket ...15068
      Bucket positioner and boom positioner ...15069
    Cab and its attachments ...15070
      ROPS cab ...15070
    Electrical system ...15071
      Engine control system ...15071
      Preheating system ...15073
      Engine power mode selector circuit ...15075
      Engine output limit function ...15076
      Automatic warm-up function ...15077
      Parking brake control system ...15078
      System operating lamp function ...15080
      Battery disconnect switch function ...15082
      Transmission controller system ...15084
      Work equipment control system ...15119
      Machine monitor system ...15140
      Rear view monitor system ...15166
      KOMTRAX system ...15169
      System component parts ...15172
      Sensor ...15205
  20 Standard value tables ...15227
    Table of contents ...15228
    Standard service value table ...15229
      Standard value table for engine ...15229
      Standard value table for machine ...15231
  30 Testing and adjusting ...15245
    Table of contents ...15246
    General information on testing and adjusting ...15248
      Tools for testing and adjusting ...15248
      Sketch of tools for testing and adjusting ...15253
    Engine and cooling system ...15254
      Testing engine speed ...15254
      Measuring boost pressure ...15255
      Testing exhaust gas temperature ...15257
      Testing exhaust gas color ...15259
      Testing and adjusting valve clearance ...15261
      Measuring compression pressure ...15263
      Testing blowby pressure ...15267
      Testing engine oil pressure ...15269
      Testing EGR valve and KVGT driving oil pressure ...15270
      Testing fuel pressure ...15271
      Testing fuel delivery, return and leakage ...15276
      Bleeding air from fuel system ...15282
      Testing fuel circuit for leakage ...15284
      Handling cylinder cutout mode operation ...15285
      Handling no injection cranking operation ...15286
      Testing of KDPF and muffler stack for looseness and damage ...15287
      Testing of installed condition of cylinder head and manifolds ...15288
      Testing engine piping for damage and looseness ...15289
      Testing and adjusting air conditioner compressor belt tension ...15290
      Replacing alternator belt ...15291
    Power train ...15292
      Adjusting transmission output speed sensor ...15292
      Adjusting transmission input speed sensor ...15293
      Flushing procedure for torque converter and transmission hydraulic circuit ...15294
      Retrieval of disabled machine due to transmission valve failure ...15295
      Checking oil leakage from axle final drive ...15297
      Testing drive shaft for looseness, backlash, and damage ...15298
      Testing and adjusting power train oil pressure ...15299
    Steering system ...15314
      Testing directional lever ...15314
      Testing steering wheel ...15315
      Testing work equipment control lever ...15317
      Testing and adjusting steering circuit pressure ...15319
      Bleeding air from steering cylinder circuit. ...15322
      Testing and adjusting steering stopper valve ...15323
    Brake system ...15324
      Testing brake pedal ...15324
      Testing and adjusting brake pedal linkage ...15325
      Testing braking performance ...15326
      Measuring accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen gas ...15327
      Testing and adjusting of accumulator charge pressure ...15331
      Testing wheel brake oil pressure ...15333
      Testing lowering of wheel brake pressure ...15334
      Measuring wear of wheel brake disc ...15337
      Bleeding air from wheel brake circuit ...15338
      Releasing remaining pressure in brake accumulator circuit ...15339
      Testing parking brake performance ...15340
      Testing parking brake oil pressure ...15341
      Testing wear of parking brake disc ...15343
      Method of releasing parking brake manually ...15344
    Hydraulic system ...15345
      Checking fan speed ...15345
      Measuring fan pump circuit oil pressure ...15346
      Bleeding air from hydraulic fan circuit ...15347
      Testing and adjusting work equipment PPC oil pressure ...15348
      Testing and adjusting work equipment oil pressure ...15351
      Bleeding air from work equipment circuit ...15355
      Releasing remaining pressure from work equipment circuit ...15356
      Checking of E.C.S.S. accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ...15357
    Work equipment ...15361
      Testing and adjusting bucket position detection lever ...15361
      Testing and adjusting boom position detection lever ...15362
    Electrical system ...15363
      Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ...15363
      Special functions of machine monitor ...15365
      Angle adjustment of rear view camera ...15459
      Handling voltage circuit of engine controller ...15460
      Handling battery disconnect switch ...15461
      Testing diodes ...15462
    Pm clinic ...15463
      Pm Clinic service ...15463
      Check sheet ...15464
  40 Troubleshooting ...15469
    Table of contents ...15470
    General information on troubleshooting ...15480
      Troubleshooting points ...15480
      Sequence of events in troubleshooting ...15482
      Check before troubleshooting ...15484
      Inspection procedure before troubleshooting ...15486
      Preparation work for troubleshooting of electrical system ...15503
      Classification and procedures for troubleshooting ...15509
      Symptom and troubleshooting numbers ...15512
      Information in troubleshooting table ...15515
      Connector list and layout ...15517
      T-branch box and T-branch adapter table ...15533
      Procedure for troubleshooting wiring harness of pressure sensor system for open circuit ...15539
      Fuse location table ...15542
      Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ...15545
      Precautions on troubleshooting of machine monitor ...15548
      Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ...15550
      Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors) ...15555
      Fabrication of short-circuit connector (for CA1883 and CA3135) ...15556
      Failure codes table ...15557
    Troubleshooting by failure code (Display of code) ...15571
      Failure code [1500L0] Double Engagement of T/M Clutches ...15571
      Failure code [15SAL1] Release Trouble of ECMV (Forward) ...15572
      Failure code [15SALH] Malfunction of ECMV (Forward) ...15574
      Failure code [15SBL1] Release Trouble of ECMV (Reverse) ...15576
      Failure code [15SBLH] Malfunction of ECMV (Reverse) ...15578
      Failure code [15SEL1] Release Trouble of ECMV (1st) ...15580
      Failure code [15SELH] Malfunction of ECMV (1st) ...15582
      Failure code [15SFL1] Release Trouble of ECMV (2nd) ...15584
      Failure code [15SFLH] Malfunction of ECMV (2nd) ...15586
      Failure code [15SGL1] Release Trouble of ECMV (3rd) ...15588
      Failure code [15SGLH] Malfunction of ECMV (3rd) ...15590
      Failure code [15SHL1] Release Trouble of ECMV (4th) ...15592
      Failure code [15SHLH] Malfunction of ECMV (4th) ...15594
      Failure code [2F00MA] Failure of Parking Brake Circuit ...15596
      Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ...15599
      Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ...15601
      Failure code [879AKA] A/C Inner Sensor Open Circuit ...15603
      Failure code [879AKB] A/C Inner Sensor Short Circuit ...15604
      Failure code [879BKA] A/C Outer Sensor Open Circuit ...15605
      Failure code [879BKB] A/C Outer Sensor Short Circuit ...15606
      Failure code [879CKA] Ventilating Sensor Open Circuit ...15607
      Failure code [879CKB] Ventilating Sensor Short Circuit ...15608
      Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ...15609
      Failure code [879EMC] Ventilation Damper Abnormality ...15610
      Failure code [879FMC] Air Mix Damper Abnormality ...15611
      Failure code [989A00] Engine Overrun Prevention Activated ...15612
      Failure code [989L00] Engine Controller Lock Caution 1 ...15613
      Failure code [989M00] Engine Controller Lock Caution 2 ...15614
      Failure code [989N00] Engine Controller Lock Caution 3 ...15615
      Failure code [A1U0N3] HC Desorb Request 1 ...15616
      Failure code [A1U0N4] HC Desorb Request 2 ...15618
      Failure code [AA10NX] Air Cleaner Clogging ...15620
      Failure code [B@BAZG] Eng Oil Press Low ...15622
      Failure code [B@BAZK] Engine Oil Level Low ...15623
      Failure code [B@BCNS] Eng Water Overheat ...15624
      Failure code [B@BCZK] Eng Water Level Low ...15625
      Failure code [B@CENS] T/C Oil Temp. Overheat ...15627
      Failure code [B@HANS] HYD Oil Temp. Overheat ...15628
      Failure code [CA115] Eng Ne and Bkup Speed Sens Error ...15629
      Failure code [CA122] Chg Air Press Sensor High Error ...15630
      Failure code [CA123] Chg Air Press Sensor Low Error ...15632
      Failure code [CA131] Throttle Sensor High Error ...15634
      Failure code [CA132] Throttle Sensor Low Error ...15636
      Failure code [CA144] Coolant Temp Sens High Error ...15638
      Failure code [CA145] Coolant Temp Sens Low Error ...15640
      Failure code [CA153] Chg Air Temp Sensor High Error ...15642
      Failure code [CA154] Chg Air Temp Sensor Low Error ...15644
      Failure code [CA187] Sensor 2 Supply Volt Low Error ...15646
      Failure code [CA221] Ambient Press Sens High Error ...15648
      Failure code [CA222] Ambient Press Sens Low Error ...15650
      Failure code [CA227] Sensor 2 Supply Volt High Error ...15652
      Failure code [CA234] Eng Overspeed ...15653
      Failure code [CA238] Ne Speed Sensor Supply Volt Error ...15654
      Failure code [CA239] Ne Speed Sens Supply Volt High Error ...15655
      Failure code [CA271] IMV/PCV1 Short Error ...15656
      Failure code [CA272] IMV/PCV1 Open Error ...15658
      Failure code [CA295] Ambient Press Sens In Range Error ...15660
      Failure code [CA322] Inj #1(L#1) Open/Short Error ...15661
      Failure code [CA323] Inj #5(L#5) Open/Short Error ...15663
      Failure code [CA324] Inj #3(L#3) Open/Short Error ...15665
      Failure code [CA325] Inj #6(L#6) Open/Short Error ...15667
      Failure code [CA331] Inj #2(L#2) Open/Short Error ...15669
      Failure code [CA332] Inj #4(L#4) Open/Short Error ...15671
      Failure code [CA343] ECM Critical Internal Failure ...15673
      Failure code [CA351] Injectors Drive Circuit Error ...15674
      Failure code [CA352] Sensor 1 Supply Volt Low Error ...15675
      Failure code [CA356] Mass Air Flow Sensor High Error ...15677
      Failure code [CA357] Mass Air Flow Sensor Low Error ...15679
      Failure code [CA386] Sensor 1 Supply Volt High Error ...15681
      Failure code [CA428] Water in Fuel Sensor High Error ...15682
      Failure code [CA429] Water in Fuel Sensor Low Error ...15684
      Failure code [CA431] Idle Validation Sw Error ...15686
      Failure code [CA432] Idle Validation Process Error ...15689
      Failure code [CA435] Eng Oil Press Sw Error ...15692
      Failure code [CA441] Battery Voltage Low Error ...15693
      Failure code [CA442] Battery Voltage High Error ...15695
      Failure code [CA449] Rail Press Very High Error ...15696
      Failure code [CA451] Rail Press Sensor High Error ...15697
      Failure code [CA452] Rail Press Sensor Low Error ...15699
      Failure code [CA488] Chg Air Temp High Torque Derate ...15701
      Failure code [CA515] Rail Press Sens Sup Volt High Error ...15702
      Failure code [CA516] Rail Press Sens Sup Volt Low Error ...15704
      Failure code [CA553] Rail Press High Error ...15706
      Failure code [CA555] Crankcase Press High Error 1 ...15707
      Failure code [CA556] Crankcase Press High Error 2 ...15708
      Failure code [CA559] Rail Press Low Error ...15709
      Failure code [CA595] Turbo Speed High Error 2 ...15711
      Failure code [CA687] Turbo Speed Low Error ...15712
      Failure code [CA689] Eng Ne Speed Sensor Error ...15714
      Failure code [CA691] Intake Air Temp Sens High Error ...15716
      Failure code [CA692] Intake Air Temp Sens Low Error ...15718
      Failure code [CA697] ECM Internal Temp Sensor High Error ...15720
      Failure code [CA698] ECM Int Temp Sensor Low Error ...15721
      Failure code [CA731] Eng Bkup Speed Sens Phase Error ...15722
      Failure code [CA778] Eng Bkup Speed Sensor Error ...15724
      Failure code [CA1117] Persistent Data Lost Error ...15729
      Failure code [CA1664] KDOC Malfunction ...15730
      Failure code [CA1691] Regeneration Ineffective ...15733
      Failure code [CA1695] Sensor 5 Supply Volt High Error ...15736
      Failure code [CA1696] Sensor 5 Supply Volt Low Error ...15737
      Failure code [CA1843] Crankcase Press Sens High Error ...15739
      Failure code [CA1844] Crankcase Press Sens Low Error ...15741
      Failure code [CA1879] KDPF Delta P Sensor High Error ...15743
      Failure code [CA1881] KDPF Delta P Sensor Low Error ...15745
      Failure code [CA1883] KDPF Delta P Sens In Range Error ...15747
      Failure code [CA1921] KDPF Soot Load High Error 1 ...15752
      Failure code [CA1922] KDPF Soot Load High Error 2 ...15755
      Failure code [CA1942] Crankcase Press Sens In Range Error ...15759
      Failure code [CA1993] KDPF Delta Pressure Low Error ...15760
      Failure code [CA2185] Throt Sensor Sup Volt High Error ...15763
      Failure code [CA2186] Throt Sensor Sup Volt Low Error ...15765
      Failure code [CA2249] Rail Press Very Low Error ...15767
      Failure code [CA2271] EGR Valve Pos Sens High Error ...15768
      Failure code [CA2272] EGR Valve Pos Sens Low Error ...15770
      Failure code [CA2288] Turbo Speed High Error 1 ...15773
      Failure code [CA2311] IMV Solenoid Error ...15774
      Failure code [CA2349] EGR Valve Solenoid Open Error ...15775
      Failure code [CA2353] EGR Valve Solenoid Short Error ...15777
      Failure code [CA2357] EGR Valve Servo Error ...15779
      Failure code [CA2373] Exhaust Manifold Press Sens High error ...15780
      Failure code [CA2374] Exhaust Manifold Press Sens Low error ...15782
      Failure code [CA2375] EGR Orifice Temp Sens High Error ...15784
      Failure code [CA2376] EGR Orifice Temp Sens Low Error ...15786
      Failure code [CA2381] KVGT Pos Sens High Error ...15788
      Failure code [CA2382] KVGT Pos Sens Low Error ...15790
      Failure code [CA2383] KVGT Solenoid Open Error ...15793
      Failure code [CA2386] KVGT Solenoid Short Error ...15795
      Failure code [CA2387] KVGT Servo Error ...15797
      Failure code [CA2554] Exh Manifold Press Sens In Range Error ...15798
      Failure code [CA2555] Grid Htr Relay Volt Low Error ...15799
      Failure code [CA2556] Grid Htr Relay Volt High Error ...15801
      Failure code [CA2637] KDOC Face Plugging ...15803
      Failure code [CA2639] Manual Stationary Regeneration Request ...15805
      Failure code [CA2961] EGR Orifice Temp High Error 1 ...15808
      Failure code [CA2973] Chg Air Press Sensor In Range Error ...15809
      Failure code [CA3133] KDPF Outlet Press Sens High Error ...15810
      Failure code [CA3134] KDPF Outlet Press Sens Low Error ...15812
      Failure code [CA3135] KDPF Outlet Press Sens In Range Error ...15814
      Failure code [CA3251] KDOC Inlet Temp High Error ...15818
      Failure code [CA3253] KDOC Temp Error - Non Regeneration ...15821
      Failure code [CA3254] KDOC Outlet Temp High Error 1 ...15824
      Failure code [CA3255] KDPF Temp Error - Non Regeneration ...15827
      Failure code [CA3256] KDPF Outlet Temp High Error 1 ...15830
      Failure code [CA3311] KDOC Outlet Temp High Error 2 ...15833
      Failure code [CA3312] KDPF Outlet Temp High Error 2 ...15836
      Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ...15839
      Failure code [CA3314] KDOC Inlet Temp Sens High Error ...15842
      Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ...15846
      Failure code [CA3316] KDOC Outlet Temp Sens Low Error ...15851
      Failure code [CA3317] KDOC Outlet Temp Sens High Error ...15854
      Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ...15858
      Failure code [CA3319] KDPF Outlet Temp Sens High Error ...15863
      Failure code [CA3321] KDPF Outlet Temp Sens Low Error ...15867
      Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ...15870
      Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ...15874
      Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ...15876
      Failure code [CA3741] Rail Press Valve Trip Error ...15878
      Failure code [D150KA] Disconnection of Emerg. Steering Relay ...15879
      Failure code [D150KB] Ground Fault of Emerg. Steering Relay ...15881
      Failure code [D150KY] Hot Short of Emergency Steering Relay ...15883
      Failure code [D160KA] Disconnection of Backup Lamp Relay Output ...15885
      Failure code [D160KB] Ground Fault of Backup Lamp Relay Output ...15887
      Failure code [D160KY] Hot Short of Backup Lamp Relay Output ...15889
      Failure code [D191KA] Disconnection of Neutral Output Relay ...15891
      Failure code [D191KB] Ground Fault of Neutral Output Relay ...15894
      Failure code [D191KY] Hot Short of Neutral Output Relay ...15897
      Failure code [D192KA] Disconnection of ECSS Solenoid ...15899
      Failure code [D192KB] Ground Fault of ECSS Solenoid ...15901
      Failure code [D192KY] Hot Short of ECSS Solenoid ...15902
      Failure code [D19JKZ] Personal Code Relay Abnormality ...15903
      Failure code [D1E6KA] Disconnection of Parking Brake Relay ...15905
      Failure code [D1E6KB] Ground Fault of Parking Brake Relay ...15907
      Failure code [D1E6KY] Hot Short of Parking Brake Relay ...15909
      Failure code [D5ZHKA] Failure of Key SW C Signal ...15911
      Failure code [D5ZHKB] Key SW C Signal Short Circuit ...15913
      Failure code [D5ZHKZ] Failure of Key SW C Signal ...15915
      Failure code [D5ZHL6] Disconnection of Key SW C ...15917
      Failure code [D811MC] KOMTRAX Error ...15919
      Failure code [D862KA] GPS Antenna Open Circuit ...15920
      Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...15921
      Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...15923
      Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ...15925
      Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ...15926
      Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ...15927
      Failure code [DAF0MB] Monitor ROM Abnormality ...15928
      Failure code [DAF0MC] Monitor Error ...15929
      Failure code [DAF3KK] Controller Power Source Low (MON) ...15930
      Failure code [DAF8KB] Camera Power Supply Short Circuit ...15932
      Failure code [DAFDKB] Monitor 12V Power Output Short Circuit ...15933
      Failure code [DAFGMC] GPS Module Error ...15935
      Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ...15936
      Failure code [DAFLKB] Operating Lamp Short Circuit (MON) ...15938
      Failure code [DAFQKR] CAN2 Discon (Monitor) ...15940
      Failure code [DAQ0KK] Controller Power Source Low (T/M) ...15941
      Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ...15944
      Failure code [DAQ0MC] T/M Con Error ...15945
      Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) ...15946
      Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ...15948
      Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay ...15951
      Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) ...15953
      Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) ...15954
      Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ...15956
      Failure code [DAQQKR] CAN2 Discon (Transmission Con) ...15958
      Failure code [DAQRKR] CAN1 Discon (Transmission Con) ...15959
      Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ...15960
      Failure code [DAZ9KQ] A/C Model Selection Abnormality ...15961
      Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ...15962
      Failure code [DB2QKR] CAN2 Discon (Engine Con) ...15963
      Failure code [DB2RKR] CAN1 Discon (Engine Con) ...15968
      Failure code [DB90KK] Drop in BBC Controller Main Power Source ...15974
      Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) ...15976
      Failure code [DB90MC] BBC Error ...15977
      Failure code [DB91KA] Disconnection of Key SW ACC (BBC) ...15978
      Failure code [DB92KK] Solenoid Power Source Low (BBC) ...15980
      Failure code [DB95KX] Failure of 5 V Power Source 1 ...15982
      Failure code [DB96KX] Failure of 5 V Power Source 2 ...15986
      Failure code [DB99KQ] Inconsistency of Model Selection (BBC) ...15990
      Failure code [DB9LKA] Operating Lamp Open Circuit (BBC) ...15991
      Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) ...15993
      Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) ...15995
      Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) ...15996
      Failure code [DB9RMA] Inconsistency of Option Selection (BBC) ...15997
      Failure code [DBE5KX] Failure of 5 V Power Source ...15998
      Failure code [DBE6KX] Failure of 24 V Power Source ...16000
      Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ...16002
      Failure code [DDAAL6] Discon Engine Shutdown Secondary Switch ...16006
      Failure code [DDB6L4] Neutral Signal Malfunction ...16008
      Failure code [DDD1LD] Failure of Bucket Positioner Set Switch ...16011
      Failure code [DDK3KA] FNR SW Input Signal Disconnection ...16015
      Failure code [DDK3KB] FNR SW Input Signal Short Circuit ...16020
      Failure code [DDK6KA] FNR Lever Input Signal Disconnection ...16024
      Failure code [DDK6KB] FNR Lever Input Signal Short Circuit ...16027
      Failure code [DDNRKY] Hot Short of Work Equipment Lock SW ...16029
      Failure code [DDT0L4] Failure of Shift Mode Select SW ...16033
      Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal ...16037
      Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal ...16041
      Failure code [DDW9LD] Ground Fault of Kickdown Switch ...16045
      Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW ...16049
      Failure code [DF10KA] Disconnection of Shift Lever Input ...16053
      Failure code [DF10KB] Ground Fault of Shift Lever Input ...16055
      Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor ...16058
      Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor ...16060
      Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor ...16062
      Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ...16064
      Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor ...16065
      Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor ...16067
      Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor ...16069
      Failure code [DH21KA] Failure of Loader Pump Press. Sensor ...16071
      Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit ...16073
      Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit ...16075
      Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor ...16077
      Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor ...16079
      Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor ...16081
      Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor ...16083
      Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor ...16086
      Failure code [DHT8KA] Failure of Steering Pump Press. Sensor ...16088
      Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit ...16090
      Failure code [DHT8ZG] Steering Oil Pressure Low ...16092
      Failure code [DHUDKA] Failure of Emrg. Steering Press. Sensor ...16093
      Failure code [DHUDKB] Emrg. Steering Press. S. Short Circuit ...16095
      Failure code [DJF1KA] Disconnection of Fuel Level Sensor ...16097
      Failure code [DK55KA] Failure of FNR Lever Potentio ...16099
      Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ...16102
      Failure code [DK55L5] Failure of FNR Lever Potentio ...16104
      Failure code [DK59KA] Failure of Boom Lever Potentio (Main) ...16105
      Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) ...16111
      Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree ...16116
      Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub) ...16123
      Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) ...16129
      Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) ...16134
      Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) ...16139
      Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree ...16144
      Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) ...16151
      Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) ...16156
      Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ...16161
      Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ...16166
      Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree ...16170
      Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) ...16176
      Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) ...16181
      Failure code [DK5KKA] Failure of 4th Lever Potentio (Main) ...16185
      Failure code [DK5KKY] Hot Short of 4th Lever Potentio (Main) ...16190
      Failure code [DK5KL8] 4th Lever Potentio (Main & Sub) Disagree ...16194
      Failure code [DK5LKA] Failure of 4th Lever Potentio (Sub) ...16200
      Failure code [DK5LKY] Hot Short of 4th Lever Potentio (Sub) ...16205
      Failure code [DKA0KA] Failure of Boom Angle Sensor ...16209
      Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit ...16211
      Failure code [DKA0L0] Boom Angle Sensor Dislocation ...16213
      Failure code [DKA1KA] Failure of Bucket Angle Sensor ...16215
      Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit ...16218
      Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor ...16220
      Failure code [DLF1LC] Failure of T/M Input Speed Sensor ...16222
      Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor ...16224
      Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor ...16226
      Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main) ...16228
      Failure code [DLT3LC] Failure of Output Speed Sensor (Main) ...16230
      Failure code [DPQ1KR] LIN Discon (Switch Panel) ...16232
      Failure code [DPQ2KR] LIN Discon (LED Unit) ...16235
      Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ...16238
      Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ...16241
      Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator ...16242
      Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. ...16246
      Failure code [DV00KB] Ground Fault of Buzzer Output ...16250
      Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) ...16252
      Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise) ...16254
      Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) ...16256
      Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) ...16258
      Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) ...16260
      Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) ...16262
      Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) ...16264
      Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) ...16266
      Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) ...16268
      Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) ...16270
      Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) ...16272
      Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) ...16274
      Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid ...16276
      Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. ...16277
      Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. ...16279
      Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ...16280
      Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid ...16282
      Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ...16284
      Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ...16286
      Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ...16290
      Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ...16294
      Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ...16298
      Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) ...16302
      Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ...16306
      Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. ...16310
      Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ...16312
      Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ...16314
      Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid ...16316
      Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid ...16318
      Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid ...16320
      Failure code [DXANKA] Disconnection of Steering Pump EPC Sol. ...16321
      Failure code [DXANKB] Ground Fault of Steering Pump EPC Solenoid ...16323
      Failure code [DXANKY] Hot Short of Steering Pump EPC Solenoid ...16325
      Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ...16326
      Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ...16328
      Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) ...16330
      Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) ...16332
      Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) ...16334
      Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) ...16336
      Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) ...16338
      Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) ...16340
      Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) ...16342
      Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ...16344
      Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) ...16345
      Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) ...16347
      Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) ...16349
      Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ...16351
      Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) ...16353
      Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) ...16355
      Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward) ...16356
      Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) ...16358
      Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) ...16360
      Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) ...16362
      Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) ...16364
      Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ...16366
      Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) ...16368
      Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) ...16370
      Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ...16372
      Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ...16374
      Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ...16376
      Failure code [DXJEKA] Disconnection of 4th EPC Solenoid (EXT) ...16378
      Failure code [DXJEKB] Ground Fault of 4th EPC Solenoid (EXT) ...16380
      Failure code [DXJEKY] Hot Short of 4th EPC Solenoid (EXT) ...16382
      Failure code [DXJFKA] Disconnection of 4th EPC Solenoid (RET) ...16384
      Failure code [DXJFKB] Ground Fault of 4th EPC Solenoid (RET) ...16386
      Failure code [DXJFKY] Hot Short of 4th EPC Solenoid (RET) ...16388
      Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor ...16390
      Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor ...16393
      Failure code [DY30ME] Emerg. Steering Long-Time Activated ...16397
      Failure code [H2K0KA] Failure of Quick Coupler Lock Signal ...16399
      Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal ...16402
      Failure code [LA00L3] Failure of Fan Reverse ...16404
    Troubleshooting of electrical system (E-mode) ...16405
      E-1 Engine does not start ...16405
      E-2 Manual preheating system does not work ...16412
      E-3 Automatic preheating system does not work ...16415
      E-4 While preheating is working, preheating monitor does not light up ...16417
      E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing ...16419
      E-6 LCD unit on machine monitor displays nothing ...16422
      E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ...16424
      E-8 LCD on machine monitor does not display properly ...16426
      E-9 Meter unit display on machine monitor is abnormal ...16428
      E-10 Night lighting lamp of meter unit on machine monitor is abnormal ...16431
      E-11 Caution LED on machine monitor is abnormal ...16434
      E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly ...16436
      E-13 Two switches operation of switch panel on machine monitor does not function ...16438
      E-14 Switch panel buzzer of machine monitor is abnormal ...16441
      E-15 Rear view monitor does not light up or backlight flickers ...16443
      E-16 Rear view monitor images are not displayed clearly ...16446
      E-17 Rear view monitor brightness cannot be adjusted ...16449
      E-18 Night lighting lamp of rear view monitor is abnormal ...16452
      E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly ...16454
      E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position ...16455
      E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light ...16459
      E-22 Air cleaner clogging indicator lamp does not light ...16461
      E-23 Radiator coolant level caution lamp does not light ...16462
      E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil temperature caution lamp does not light ...16464
      E-25 Indication of torque converter oil temperature gauge does not increase, or torque converter oil temperature caution lamp does not light ...16466
      E-26 Fuel level gauge does not indicate correct level ...16467
      E-27 Seat belt caution lamp indication is abnormal ...16469
      E-28 Horn does not sound ...16470
      E-29 Horn does not stop sounding ...16473
      E-30 Alarm buzzer does not sound ...16475
      E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ...16476
      E-32 Kickdown does not work when kickdown switch is turned ON ...16477
      E-33 The hold switch does not work when it is pressed ...16479
      E-34 Parking brake does not work even if it is applied, or the brake drags when parking brake is released and FR drive is operated ...16481
      E-35 Transmission cut-off mode is not selected or not released ...16484
      E-36 Transmission cut-off setting cannot be released ...16486
      E-37 Directional selector (FNR) switch mode is not selected or not released ...16488
      E-38 When operating engine power selection switch, engine power selection function does not operate properly ...16490
      E-39 Flow of loader pump does not increase from the minimum rate ...16492
      E-40 ECSS function cannot be selected or cannot be released ...16493
      E-41 None of headlamp, clearance lamp, and tail lamp lights ...16495
      E-42 Clearance lamp and tail lamp do not light up or go out ...16497
      E-43 Both "High and Low beams" of headlamp do not light up or go out ...16500
      E-44 The headlamp "Low beam" does not light up or go out ...16504
      E-45 The headlamp "High beam" does not light up or go out ...16506
      E-46 Front working lamp does not light up or go out ...16508
      E-47 Rear working lamp does not light up or go out ...16511
      E-48 All of turn signal lamps and hazard lamps do not light up or go out ...16514
      E-49 Turn signal lamps do not light up or go out ...16517
      E-50 Hazard lamp does not light up or go out ...16520
      E-51 Brake lamp does not light up or stays lighted ...16523
      E-52 Backup lamp does not light or continues to light ...16526
      E-53 Backup buzzer does not sound or continues to sound ...16529
      E-54 Front wiper does not operate ...16531
      E-55 Rear wiper does not operate ...16534
      E-56 Window washer does not operate ...16536
      E-57 KOMTRAX system does not operate properly ...16539
    Troubleshooting of hydraulic and mechanical system (H-mode) ...16541
      Information described in troubleshooting table (H-mode) ...16541
      System chart of hydraulic and mechanical systems ...16542
      Failure mode and cause table ...16544
      H-1 Machine does not start ...16550
      H-2 Torque converter lockup clutch is not disengaged (engine stalls) ...16553
      H-3 Torque converter lockup clutch is not engaged ...16554
      H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift ...16555
      H-5 Large shock is made when machine starts or gear is shifted ...16558
      H-6 Machine starts or gear speed shifts with long time lag ...16561
      H-7 Torque converter oil temperature is high ...16563
      H-8 Machine does not turn ...16566
      H-9 Turning response is poor ...16568
      H-10 Steering wheel is heavy to turn ...16570
      H-11 Machine sways or large shocks are made while machine turns ...16571
      H-12 Turning radius differs between right and left turns ...16573
      H-13 Wheel brakes do not work or are weak ...16574
      H-14 Wheel brakes are not released or drag ...16575
      H-15 Parking brake does not work or it is weak ...16576
      H-16 Parking brake is not released or drags (including emergency release system) ...16577
      H-17 Boom does not rise ...16578
      H-18 Boom moves slow or boom lacks lifting force ...16580
      H-19 Rising boom slows down at certain height ...16582
      H-20 Lift cylinders do not serve to hold bucket on ground ...16583
      H-21 Hydraulic drift of boom is large ...16584
      H-22 Boom moves up and down during operation ...16585
      H-23 Bucket does not tilt back ...16586
      H-24 Bucket moves slow or bucket lacks tilt-back force ...16588
      H-25 Bucket decelerates during tilt-back operation ...16590
      H-26 Bucket cylinder does not hold bucket on ground ...16591
      H-27 Hydraulic drift of bucket is large ...16592
      H-28 Bucket tilts back and forth during carrying load (work equipment valve in "HOLD") ...16593
      H-29 Boom and bucket control levers do not move smoothly and heavy to move ...16594
      H-30 Operating work equipment causes engine speed to lower significantly or engine to stall ...16596
      H-31 Large shocks are made when work equipment starts to move and stops ...16597
      H-32 When certain work equipment stalls hydraulically, other work equipment moves ...16599
      H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces ...16600
      H-34 Air conditioner does not work while cooling fan rotates in reverse mode ...16601
      H-35 Fan speed is abnormal (too high or low, or fan doe not rotate) ...16602
      H-36 Unusual noise is heard from around fan ...16603
    Troubleshooting of engine (S-mode) ...16604
      Information described in troubleshooting table (S mode) ...16604
      S-1 Engine does not crank when starting switch is turned to "START" position ...16605
      S-2 Engine cranks but no exhaust smoke comes out ...16606
      S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) ...16607
      S-4 Engine startability is poor ...16608
      S-5 Engine does not pick up smoothly ...16610
      S-6 Engine stops during operation ...16612
      S-7 Engine runs rough or is unstable ...16614
      S-8 Engine lacks power ...16615
      S-9 Exhaust smoke is black (KDPF gets clogged in a short time) ...16617
      S-10 Engine oil consumption is excessive ...16619
      S-11 Engine oil becomes contaminated early ...16620
      S-12 Fuel consumption is excessive ...16621
      S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ...16622
      S-14 Oil pressure drops ...16623
      S-15 Fuel mixes into engine oil ...16624
      S-16 Water mixes into engine oil (milky) ...16625
      S-17 Coolant temperature rises too high (overheating) ...16626
      S-18 Unusual noise is heard ...16627
      S-19 Vibration is excessive ...16628
      S-20 Air cannot be bled from fuel circuit ...16629
      S-21 Active regeneration is executed frequently ...16630
      S-22 Active regeneration takes time ...16631
      S-23 White smoke is exhausted during active regeneration ...16632
  50 Disassembly and assembly ...16633
    Table of contents ...16634
    General information on disassembly and assembly ...16636
      How to read this manual ...16636
      Coating materials list ...16638
      Special tools list ...16642
      Sketches of special tools ...16645
    Engine and cooling system ...16652
      Removal and installation of supply pump assembly ...16652
      Removal and installation of injector assembly ...16655
      Removal and installation of cylinder head assembly ...16666
      Removal and installation of engine hood assembly ...16685
      Removal and installation of grille assembly ...16688
      Removal and installation of cooling system assembly ...16689
      Removal and installation of radiator core assembly ...16692
      Removal and installation of aftercooler ...16695
      Removal and installation of hydraulic oil cooler assembly ...16697
      Removal and installation of fuel cooler assembly ...16698
      Removal and installation of engine, torque converter and transmission assemblies ...16699
      Disconnection and connection of engine, torque converter and transmission assembly ...16706
      Removal and installation of engine front oil seal ...16708
      Removal and installation of engine rear oil seal ...16711
      Removal and installation of cooling fan and fan motor assembly ...16714
      Removal and installation of KDPF assembly ...16716
      Disassembly and assembly of KDPF assembly ...16719
      Removal and installation of KCCV assembly ...16728
      Removal and installation of air cleaner assembly ...16729
      Removal and installation of fuel tank assembly ...16731
    Power train ...16734
      Disassembly and assembly of torque converter assembly ...16734
      Disassembly and assembly of transmission assembly ...16741
      Disassembly and assembly of transmission clutch pack assembly ...16754
      Disassembly and assembly of differential assembly ...16768
      Disassembly and assembly of parking brake assembly ...16786
      Removal and installation of front axle assembly ...16794
      Removal and installation of rear axle assembly ...16795
      Disassembly and assembly of axle housing assembly ...16798
    Steering system ...16807
      Removal and installation of steering valve assembly ...16807
    Brake system ...16809
      Removal and installation of parking brake disc and plate ...16809
    Undercarriage and frame ...16812
      Removal and installation of center hinge pin ...16812
      Removal and installation of counterweight assembly ...16820
      Removal and installation of full-length fender assembly ...16822
    Hydraulic system ...16823
      Removal and installation of hydraulic tank assembly ...16823
      Removal and installation of work equipment controll valve assembly ...16826
      Removal and installation of power train pump and work equipment hydraulic pump assembly ...16829
      Removal and installation of steering pump and cooling fan pump assembly ...16830
      Disassembly and assembly of hydraulic cylinder assembly ...16832
    Work equipment ...16839
      Removal and installation of work equipment assembly ...16839
    Cab and its attachments ...16844
      Removal and installation of operator's cab and floor frame assembly ...16844
      Removal and installation of operator's cab glass (stuck window glass) ...16848
      Removal and installation of operator's seat assembly ...16856
      Removal and installation of seat belt ...16858
    Electrical system ...16859
      Removal and installation of machine monitor assembly ...16859
      Removal and installation of engine controller assembly ...16860
      Removal and installation of work equipment controller assembly ...16861
      Removal and installation of transmission controller assembly ...16863
      Removal and installation of monitor controller assembly ...16864
      Removal and installation of mass air flow and temperature sensor ...16866
      Removal and installation of KOMTRAX terminal assembly ...16867
  60 Maintenance standard ...16869
    Table of contents ...16870
    Engine and cooling system ...16871
      Engine related parts ...16871
      Cooling fan pump ...16872
      Cooling fan motor ...16875
    Power train ...16877
      Drive shaft ...16877
      Torque converter ...16878
      Transmission ...16880
      Transmission control valve ...16887
      Forward and reverse clutch ECMV and gear speed clutch ECMV ...16888
      Lockup clutch ECMV ...16889
      Main relief and torque converter relief valve ...16890
      Differential ...16891
      Limited slip differential ...16894
      Final drive ...16898
    Steering system ...16900
      Steering column ...16900
      Steering pump ...16901
      Steering valve ...16905
      Steering cylinder ...16907
      Emergency steering pump ...16909
    Brake system ...16910
      Charge valve ...16910
      Brake ...16912
      Parking brake ...16914
      Parking brake solenoid valve ...16915
    Undercarriage and frame ...16916
      Axle mount and center hinge pin ...16916
    Hydraulic system ...16920
      Hydraulic tank ...16920
      Double type gear pump ...16921
      Work equipment pump ...16922
      Control valve ...16927
      Stabilizer valve ...16938
    Work equipment ...16939
      Work equipment linkage ...16939
      Bucket ...16942
      Work equipment cylinder ...16943
  80 Appendix ...16945
    Table of contents ...16946
    Air conditioner components ...16947
      Precautions for refrigerant ...16947
      Air conditioner component ...16948
      Configuration and function of refrigeration cycle ...16950
      Outline of refrigeration cycle ...16951
      Air conditioner unit ...16953
      Dual pressure switch ...16958
      Air conditioner controller ...16959
      Compressor ...16960
      Condenser ...16961
      Receiver drier ...16962
      Sunlight sensor ...16964
      Outer temperature sensor (outside air temperature sensor) ...16965
      Procedure for testing and troubleshooting ...16966
      Circuit diagram and arrangement of connector pins ...16968
      System diagram ...16970
      Parts and connectors layout ...16972
      Testing with self-diagnosis function ...16977
      Testing temperature control system ...16980
      Testing vent (mode) changeover ...16982
      Testing FRESH/RECIRC air changeover ...16984
      Check evaporator temperature sensor ...16986
      Testing relays ...16988
      Troubleshooting chart 1 ...16990
      Troubleshooting chart 2 ...16991
      Information in troubleshooting table ...16993
      Failure code list related to air conditioner ...16994
      Failure code [879AKA] A/C Inner Sensor Open Circuit ...16995
      Failure code [879AKB] A/C Inner Sensor Short Circuit ...16997
      Failure code [879BKA] A/C Outer Sensor Open Circuit ...16999
      Failure code [879BKB] A/C Outer Sensor Short Circuit ...17001
      Failure code [879CKA] Ventilating Sensor Open Circuit ...17003
      Failure code [879CKB] Ventilating Sensor Short Circuit ...17005
      Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ...17007
      Failure code [879EMC] Ventilation Damper Abnormality ...17009
      Failure code [879FMC] Air Mix Damper Abnormality ...17012
      A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) ...17015
      A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ...17018
      A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ...17021
      A-4 Troubleshooting for FRESH/RECIRC air changeover ...17024
      Troubleshooting with gauge pressure ...17026
      Connection of service tool ...17029
      Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ...17031
      Handling of compressor oil ...17033
  90 Diagrams and drawings ...17035
    Table of contents ...17036
    Hydraulic circuit diagram ...17037
      Symbols in hydraulic circuit diagram ...17037
      Power train hydraulic circuit diagram ...17041
      Hydraulic circuit diagram...17043
    Electric circuit diagram ...17044
      Symbols in electric circuit diagram ...17044
      Electric circuit diagram of machine body...17048
      Electric circuit diagram of floor...17054
  INDEX...17070
SEN06411-00 - Wheel Loader WA380-6, WA380Z-6 Shop Manual...17084
  Cover...17084
  00 Index and foreword...0
    Index...17085
      Composition of shop manual...17086
      Table of contents...17088
    Foreword and general information...17101
      Safety notice...17102
      How to read the shop manual...17107
      Explanation of terms for maintenance standard...17109
      Handling of electric equipment and hydraulic component...17111
      Handling of connectors newly used for engines...17120
      How to read electric wire code...17123
      Precautions when carrying out operation...17126
      Method of disassembling and connecting push-pull type coupler...17129
      Standard tightening torque table...17132
      Conversion table...17136
  01 Specification...17143
    Specification and technical data...0
      Specification dimension drawing...17144
      Specifications...17146
      Weight table...17154
      Table of fuel, coolant and lubricants...17158
  10 Structure, function and maintenance standard...0
    Engine and cooling system...17161
      Engine mount and transmission mount...17162
      Cooling system...17163
      Cooling fan pump...17165
      Brake and fan pump...17172
      Cooling fan motor...17173
    Power train...17187
      Power train...17189
      Power train system diagram...17190
      Drive shaft...17193
      Power train piping diagram...17194
      Torque converter...17196
      Transmission...17204
      Flow control valve...17238
      Valve assembly...17240
      ECMV...17241
      Main relief valve and torque converter relief valve...17249
      Differential...17253
      Limited slip differential...17257
      Final drive...17264
    Steering system...17269
      Steering piping diagram...17270
      Steering column...17272
      Steering pump...17274
      Steering valve...17294
      Orbit-roll valve...17309
      Stop valve...17317
      Steering relief valve...17318
      Steering cylinder...17319
      Emergency steering motor...17321
      Emergency steering pump...17322
      Joystick steering lever linkage...17323
      Steering electric lever...17324
      Joystick EPC valve...17325
    Brake system...17327
      Brake piping diagram...17328
      Charge valve...17330
      Brake valve...17337
      Accumulator (for brake)...17342
      Brake...17344
      Parking brake control...17349
      Parking brake...17350
      Parking brake solenoid valve...17352
      Emergency parking brake release valve...17354
    Undercarriage and frame...17357
      Axle mount and center hinge pin...17358
      Tires...17363
    Hydraulic system, Part 1...17365
      Hydraulic piping diagram...17366
      Work equipment control lever linkage...17372
      Hydraulic tank...17375
      Power train pump...17379
      Work equipment pump...17380
      Work equipment control valve...17402
      CLSS...17430
      Each function and operation of each valve...17434
    Hydraulic system, Part 2...17467
      PPC valve...17468
      Stabilizer valve...17474
      Accumulator (for PPC circuit)...17480
      Accumulator (for ECSS)...17481
      Work equipment PPC cut-off solenoid valve...17482
    Work equipment...17485
      Work equipment linkage...17486
      Bucket...17490
      Bucket positioner and boom kick-out...17492
      Work equipment cylinder...17498
    Cab and its attachments...17501
      Cab...17503
      Air conditioner...17504
    Electrical system, Part 1...17525
      Machine monitor system...17526
      Machine monitor...17534
    Electrical system, Part 2...17593
      Electrical system (Transmission controller system)...17594
      Transmission controller...17638
      Electrical system (Work equipment controller system)...17642
      Work equipment controller...17648
    Electrical system, Part 3...17651
      Electric transmission control...17652
      Kickdown switch and hold switch...17656
      Multi-function knob...17658
      Joystick steering knob...17659
      KOMTRAX terminal system...17660
      Engine starting circuit...17662
      Engine stopping circuit...17666
      Preheating circuit...17668
      Engine power mode selector circuit...17669
      Engine output derating function...17670
      Automatic warm-up function...17670
      Parking brake circuit...17672
      Sensor...17674
  20 Standard value table...0
    Standard service value table...17685
      Standard service value table for engine...17686
      Standard service value table for chassis...17688
  30 Testing and adjusting...0
    Testing and adjusting, Part 1...17701
      Tools for testing, adjusting, and troubleshooting...17703
      Testing engine speed...17710
      Testing exhaust gas color...17712
      Adjusting valve clearance...17714
      Testing compression pressure...17719
      Testing blow-by pressure...17725
      Testing engine oil pressure...17726
      Testing intake air (boost) pressure1...17728
      Handling fuel system equipment...17730
      Releasing residual pressure in fuel system...17730
      Testing fuel pressure...17731
      Testing fuel delivery, return and leak amount...17736
      Bleeding air from fuel circuit...17744
      Testing leakage in fuel system...17745
      Handling reduced cylinder mode operation...17746
      Handling no-injection cranking operation...17746
      Handling controller voltage circuit1...17747
      Testing muffler (main body) and muffler stack for looseness or damage...17747
      Testing muffler for functions...17748
      Testing cylinder head and manifold parts for tightness...17748
      Testing engine piping for damage and tightness...17749
      Testing and adjusting air conditioner compressor belt tension...17750
      Replacing alternator belt...17751
      Adjusting transmission speed sensor...17753
      Adjusting length of directional lever...17754
      Adjusting length of gearshift lever...17754
      Testing directional lever...17755
      Testing and adjusting power train oil pressure...17756
      Procedure for flushing torque converter and transmission hydraulic circuit...17785
      Method of moving machine when transmission valve is broken...17786
      Testing axle end for oil leakage...17790
      Testing drive shaft for looseness, backlash and damage...17790
      Testing and adjusting steering stop valve...17791
      Testing and adjusting steering wheel...17793
      Testing and adjusting steering oil pressure...17795
      Bleeding air from steering circuit...17798
    Testing and adjusting, Part 2...17801
      Testing hydraulic drive fan...17803
      Bleeding air from hydraulic drive fan circuit...17807
      Testing brake pedal...17810
      Testing and adjusting brake pedal linkage...17811
      Testing brake performance...17812
      Testing and adjusting accumulator charge pressure...17813
      Testing wheel brake oil pressure...17815
      Testing wheel brake oil pressure drop...17816
      Testing wear of wheel brake disc...17818
      Bleeding air from wheel brake circuit...17819
      Releasing residual pressure in brake accumulator circuit...17820
      Testing parking brake performance...17821
      Testing parking brake oil pressure...17822
      Testing wear of parking brake disc...17824
      Method of releasing parking brake manually...17825
      Testing and adjusting work equipment control lever...17826
      Testing and adjusting worke quipment PPC oil pressure...17827
      Testing and adjusting work equipment oil pressure...17833
      Bleeding air from work equipment circuit...17837
      Releasing residual pressure in work equipment circuit...17838
      Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator...17840
      Testing and adjusting bucket positioner...17846
      Testing and adjusting boom kick-out...17848
      Checking proximity switch operation pilot lamp...17849
      Procedure for testing diodes...17850
      Preparation work for troubleshooting for electric system...17851
      How to start operation of KOMTRAX terminal...17860
      Lamp display of KOMTRAX terminal...17865
    Testing and adjusting, Part 3...17869
      Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor...17871
      Special functions of machine monitor (EMMS)...17873
      Pm-clinic inspection table...17942
  40 Troubleshooting...0
    Failure code table and fuse locations...17949
      Failure code table...17950
      Fuse locations...17967
    General information on troubleshooting...17973
      Points to remember when troubleshooting...17974
      Sequence of events in troubleshooting...17975
      Testing before troubleshooting...17977
      Classification and procedures of troubleshooting...17978
      Information contained in troubleshooting table...17981
      Connection table for connector pin numbers...17983
      T- branch box and T- branch adapter table...18019
    Troubleshooting by failure code (Display of code), Part 1...18023
      Failure code [1500L0] (TORQFLOW transmission: Double meshing)...18025
      Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)...18026
      Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)...18028
      Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)...18030
      Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)...18032
      Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)...18034
      Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)...18036
      Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)...18038
      Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)...18040
      Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)...18042
      Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)...18044
      Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)...18046
      Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)...18048
      Failure code [2F00MA] (Parking brake: Malfunction)...18050
      Failure code [2G43ZG] (Accumulator: Low oil pressure)...18053
      Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)...18057
    Troubleshooting by failure code (Display of code), Part 2...18061
      Failure code [AA1ANX] (Air cleaner: Clogging)...18064
      Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)...18067
      Failure code [AB00MA] (Alternator: Malfunction)...18071
      Failure code [B@BAZG] (Rotation derating by low engine oil pressure)...18075
      Failure code [B@BAZK] (Engine oil: Low level)...18076
      Failure code [B@BCNS] (Coolant: Overheating)...18077
      Failure code [B@BCZK] (Coolant: Low level)...18079
      Failure code [B@BEBF] (Water in fuel error)...18082
      Failure code [B@C7NS] (Brake oil: Overheating)...18084
      Failure code [b@CENS] (Torque converter oil: Overheating)...18086
      Failure code [B@CENS] (Torque converter oil: Overheating)...18089
      Failure code [B@HANS] (Hydraulic oil: Overheating)...18092
      Failure code [CA111] (Abnormality in engine controller)...18094
      Failure code [CA115] (Engine Ne or Bkup speed sensor error)...18095
      Failure code [CA122] (Charge pressure sensor high error)...18096
      Failure code [CA123] (Charge pressure sensor low error)...18098
      Failure code [CA131] (Throttle sensor high error)...18100
      Failure code [CA132] (Throttle sensor low error)...18102
      Failure code [CA144] (Coolant sensor high error)...18104
      Failure code [CA145] (Coolant sensor low error)...18106
      Failure code [CA153] (Charge temperature sensor high error)...18108
      Failure code [CA154] (Charge temperature sensor low error)...18110
      Failure code [CA155] (Derating of speed by abnormally high charge temperature)...18112
      Failure code [CA187] (Sensor power supply 2 low error)...18114
      Failure code [CA221] (Atmospheric pressure sensor high error)...18116
      Failure code [CA222] (Atmospheric sensor low error)...18118
      Failure code [CA227] (Sensor power supply 2 high error)...18120
      Failure code [CA234] (Engine overspeed)...18121
      Failure code [CA238] (Ne speed sensor power supply error)...18122
    Troubleshooting by failure code (Display of code), Part 3...18125
      Failure code [CA271] (IMV/PCV1 Short circuit)...18127
      Failure code [CA272] (IMV/PCV1 Disconnection)...18128
      Failure code [CA322] (Injector #1 open/short error)...18130
      Failure code [CA323] (Injector #5 open/short error)...18132
      Failure code [CA324] (Injector #3 open/short error)...18134
      Failure code [CA325] (Injector #6 open/short error)...18136
      Failure code [CA331] (Injector #2 open/short error)...18138
      Failure code [CA332] (Injector #4 open/short error)...18140
      Failure code [CA342] (Calibration code inconsistency)...18142
      Failure code [CA351] (Injectors drive circuit error)...18144
      Failure code [CA352] (Sensor power supply 1 low error)...18147
      Failure code [CA386] (Sensor power supply 1 high error)...18149
      Failure code [CA428] (Abnormally high level in water sensor)...18150
      Failure code [CA429] (Abnormally low level in water sensor)...18151
      Failure code [CA431] (Idle validation switch error)...18152
      Failure code [CA432] (Idle validation action error)...18155
      Failure code [CA435] (Engine oil pressure switch error)...18157
      Failure code [CA441] (Battery voltage low error)...18158
      Failure code [CA442] (Battery voltage high error)...18162
      Failure code [CA449] Common rail pressure high error 2...18165
      Failure code [CA451] (Common rail pressure sensor high error)...18167
      Failure code [CA452] (Common rail pressure sensor low error)...18169
      Failure code [CA488] (Derating of torque by abnormally high charge temperature)...18171
      Failure code [CA553] (Common rail pressure high error 1)...18172
      Failure code [CA559] (Supply pump pressure very low error)...18173
      Failure code [CA689] (Engine Ne speed sensor error)...18174
      Failure code [CA731] (Engine Bkup speed sensor phase error)...18177
      Failure code [CA757] (All continuous data lost error)...18178
      Failure code [CA778] (Engine Bkup speed sensor error)...18182
      Failure code [CA1633] (KOMNET datalink timeout error)...18185
      Failure code [CA2185] (Throttle sensor power supply voltage high error)...18188
      Failure code [CA2186] (Throttle sensor power supply voltage low error)...18189
    Troubleshooting by failure code (Display of code), Part 4...18191
      Failure code [CA2249] (Supply pump pressure very low error 2)...18193
      Failure code [CA2311] (Abnormality in IMV solenoid)...18194
      Failure code [CA2555] (Intake heater relay disconnection error)...18196
      Failure code [CA2556] (Intake heater relay short circuit error)...18199
      Failure code [D150KA] (Emergency steering relay: Disconnection)...18202
      Failure code [D150KB] (Emergency steering relay: Short circuit)...18205
      Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)...18208
      Failure code [D160KA] (Backup lamp relay: Disconnection)...18211
      Failure code [D160KB] (Backup lamp relay: Short circuit)...18214
      Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)...18217
      Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)...18219
      Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)...18221
      Failure code [D192KA] (ECSS solenoid: Disconnection)...18223
      Failure code [D192KB] (ECSS solenoid: Short circuit)...18224
      Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)...18225
      Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection)...18226
      Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit)...18228
      Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line)...18230
      Failure code [D5ZHKA] (Terminal C signal: Disconnection)...18233
      Failure code [D5ZHKB] (Terminal C signal: Short circuit)...18239
      Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)...18244
      Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)...18251
      Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)...18256
      Failure code [DAF3KK] (Machine monitor: Low source voltage (input)...18258
      Failure code [DAF5KP] (Machine monitor: Low output voltage)...18262
      Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system)...18266
    Troubleshooting by failure code (Display of code), Part 5...18271
      Failure code [DAQ0KK] (Transmission controller: Low source voltage)...18274
      Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)...18278
      Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)...18279
      Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)...18282
      Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)...18283
      Failure code [DAQRMA] (Transmission controller option setting: Malfunction)...18289
      Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)...18290
      Failure code [DB90KK] Work equipment controller: Low source voltage (input)...18294
      Failure code [DB90KT] Work equipment controller: Abnormality in controller...18296
      Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)...18297
      Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range...18299
      Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)...18302
      Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)...18303
      Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)...18305
      Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation)...18306
      Failure code [DD15LD] ■ switch (Panel switch 1): Switch is kept pressed for long time...18310
      Failure code [DD16LD] <> switch (Panel switch 2): Switch is kept pressed for long time...18313
      Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time...18316
      Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time...18319
      Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time...18322
      Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time...18324
      Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time...18326
      Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time...18328
      Failure code [DD1GLD] Load meter mode selector switch (+/-): Switch is kept pressed for long time...18330
      Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)...18332
      Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)...18334
      Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)...18336
      Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)...18338
    Troubleshooting by failure code (Display of code), Part 6...18343
      Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)...18346
      Failure code [DDK3KA] (Right FNR switch: Disconnection)...18349
      Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)...18352
      Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)...18355
      Failure code [DDK6KA] (FNR lever switch: Disconnection)...18357
      Failure code [DDK6KB] (FNR lever switch: Short circuit)...18364
      Failure code [DDS5KA] (Steering pressure switch: Disconnected)...18368
      Failure code [DDS5KB] (Steering pressure switch: Grounded)...18370
      Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)...18372
      Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)...18375
      Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)...18378
      Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)...18381
      Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)...18384
      Failure code [DF10KA] (Transmission shift lever switch: Disconnected)...18386
      Failure code [DF10KB] (Transmission shift lever switch: Short circuit)...18390
      Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)...18393
      Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)...18396
      Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)...18399
      Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)...18401
      Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)...18403
      Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)...18405
      Failure code [DH21KA] (Loader pump pressure sensor: Disconnection)...18408
      Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short)...18410
    Troubleshooting by failure code (Display of code), Part 7...18413
      Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)...18416
      Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)...18418
      Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)...18420
      Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)...18424
      Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)...18426
      Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)...18428
      Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)...18431
      Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)...18434
      Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)...18437
      Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)...18440
      Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)...18443
      Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)...18446
      Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)...18449
      Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)...18452
      Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)...18455
    Troubleshooting by failure code (Display of code), Part 8...18459
      Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)...18461
      Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)...18464
      Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)...18466
      Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)...18470
      Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)...18472
      Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)...18476
      Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)...18478
      Failure code [DKA0L0] (Lift arm angle sensor: Dislocation of sensor)...18480
      Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)...18482
      Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)...18484
      Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)...18486
      Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)...18490
      Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)...18492
      Failure code [DV00KB] (Alarm buzzer: Short circuit)...18494
      Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)...18496
      Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)...18498
      Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)...18500
      Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)...18502
      Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)...18503
      Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)...18504
      Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)...18506
      Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)...18507
      Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)...18508
    Troubleshooting by failure code (Display of code), Part 9...18511
      Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)...18513
      Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)...18514
      Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)...18516
      Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)...18518
      Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)...18520
      Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)...18522
      Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)...18524
      Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)...18526
      Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)...18528
      Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)...18530
      Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)...18532
      Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)...18534
      Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)...18536
      Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)...18538
      Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)...18540
      Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)...18542
      Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)...18544
      Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)...18546
      Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) (WA380-6)...18548
      Failure code [DX16KA] (Fan motor EPC solenoid: Disconnection) (WA380Z-6)...18549
      Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) (WA380-6)...18550
      Failure code [DX16KB] (Fan motor EPC solenoid: Short circuit) (WA380Z-6)...18551
      Failure code [DX16KY] (Fan motor EPC solenoid: Short circuit with power supply line) (WA380Z-6)...18553
      Failure code [DXA1KA] (Loader pump EPC solenoid: Disconnection)...18554
      Failure code [DXA1KB] (Loader pump EPC solenoid: Short circuit)...18556
      Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)...18558
      Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)...18560
      Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)...18562
      Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)...18564
      Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)...18566
      Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)...18568
    Troubleshooting by failure code (Display of code), Part 10...18571
      Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)...18574
      Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)...18576
      Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)...18578
      Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)...18580
      Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)...18582
      Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)...18584
      Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)...18586
      Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)...18588
      Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)...18590
      Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)...18592
      Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)...18594
      Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)...18596
      Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)...18598
      Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)...18600
      Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)...18602
      Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)...18604
      Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)...18606
      Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)...18608
      Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)...18610
      Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)...18612
      Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)...18614
      Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine)...18616
      Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode)...18621
    Troubleshooting of electrical system (E-mode)...18629
      Installing positions of fuses...18631
      Information in troubleshooting table...18636
      E-1 Engine does not start...18637
      E-2 Wiper does not operate...18650
      E-3 Windshield washer does not operate...18655
      E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off...18659
      E-5 Working lamp does not light up or go off...18675
      E-6 Turn signal lamp and hazard lamp do not light up or go off...18685
      E-7 Brake lamp does not light or it keeps lighting up...18697
      E-8 Backup lamp does not light or it keeps lighting up...18701
      E-9 Backup buzzer does not sound or it keeps sounding...18705
      E-10 Horn does not sound or it keeps sounding...18708
      E-11 Alarm buzzer does not sound or it keeps sounding...18712
      E-12 Air conditioner does not operate or stop...18714
      E-13 The KOMTRAX system does not work properly...18718
      E-14 When kick-down switch is turned ON, kick-down operation does not start...18721
      E-15 When hold switch is pressed, holding operation does not start...18724
      E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied...18727
      E-17 Transmission cut-off mode cannot be set or reset...18730
      E-18 Transmission cut-off set cannot be reset...18733
      E-19 FNR switch mode cannot be set or reset...18736
      E-20 Fan reverse function cannot be used or reset...18738
      E-21 Discharge from loader pump does not rise from minimum level...18740
      E-22 ECSS function cannot be used or reset...18742
      E-23 When parking brake is turned ON, parking brake indicator lamp does not light up...18744
      E-24 When emergency brake operates, brake oil pressure caution lamp does not operate...18748
      E-25 Air cleaner clogging indicator lamp does not light up...18752
      E-26 Radiator coolant level caution lamp does not light up...18755
      E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light up...18757
      E-28 Torque converter oil temperature gauge does not rise and torque converter oil temperature caution lamp does not light up...18759
      E-29 Steering oil pressure caution lamp does not light up...18761
      E-30 Abnormality in ■ switch (panel switch 1) input...18764
      E-31 Abnormality in <> switch (panel switch 2) input...18767
      名称未設定...18770
      E-32 Abnormality in < switch (panel switch 3) input...18770
      E-33 Abnormality in > switch (panel switch 4) input...18773
    Troubleshooting of hydraulic and mechanical system (H-mode)...18777
      Method of using troubleshooting chart...18779
      Table of failure modes and causes...18782
      H-1 The machine does not start...18790
      H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch]...18792
      H-3 Torque converter lockup is not switched on [Machine with lockup clutch]...18793
      H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted...18794
      H-5 Shocks are large at the times of starting and shifting gear...18796
      H-6 Time lag is large at the times of starting and shifting gear...18798
      H-7 The torque converter oil temperature is high...18800
      H-8 Steering does not turn...18801
      H-9 Steering does not turn [Machine with joystick steering]...18802
      H-10 Steering response is low...18803
      H-11 Turning, response of steering is poor [machine with joystick steering]...18804
      H-12 Steering is heavy...18805
      H-13 When machine turns, it shakes or makes large shocks...18806
      H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering]...18807
      H-15 The wheel brake does not work or does not work well...18808
      H-16 The wheel brake is not released or it drags...18809
      H-17 The parking brake does not work or does not work well...18810
      H-18 The parking brake is not released or it drags (including emergency release system)...18811
      H-19 Lift arm does not rise...18812
      H-20 Lift arm speed is low or rising force of lift arm is insufficient...18813
      H-21 When rising, the lift arm comes to move slowly at specific height...18814
      H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)...18814
      H-23 Hydraulic drifts of the lift arm is large...18814
      H-24 The lift arm wobbles during operation...18814
      H-25 Bucket does not tilt back...18815
      H-26 Bucket speed is low or tilting back force is insufficient...18816
      H-27 The bucket comes to operate slowly in the midst of tilting-back...18817
      H-28 The bucket cylinder cannot hold down the bucket...18817
      H-29 Hydraulic drifts of the bucket is large...18817
      H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”)...18817
      H-31 Lift arm and bucket control levers do not move smoothly and are heavy...18818
      H-32 During operation of the machine, engine speed lowers remarkably or engine stalls...18819
      H-33 Large shock is made when work equipment starts and stops...18819
      H-34 When work equipment circuit is relieved singly, other work equipment moves...18819
      H-35 ECSS does not operate, and pitching, bouncing occur...18820
      H-36 Fan revolution is abnormal (Fan sound/ vibration is abnormally large or engine overheats)...18821
    Troubleshooting of engine (S-mode)...18823
      Method of using troubleshooting charts...18825
      S-1 Engine does not start easily...18828
      S-2 Engine does not start...18829
      S-3 Engine does not pick up smoothly...18832
      S-4 Engine stops during operations...18833
      S-5 Engine does not rotate smoothly...18834
      S-6 Engine lacks output (or lacks power)...18835
      S-7 Exhaust smoke is black (Incomplete combustion)...18836
      S-8 Oil consumption is excessive (or exhaust smoke is blue)...18837
      S-9 Engine oil becomes contaminated quickly...18838
      S-10 Fuel consumption is excessive...18839
      S-11 Coolant contains oil (blows back or reduces)...18840
      S-12 Oil pressure drops...18841
      S-13 Oil level rises (Water, fuel in oil)...18842
      S-14 Coolant temperature rises too high (Overheating)...18843
      S-15 Abnormal noise is made...18844
      S-16 Vibration is excessive...18845
  50 Disassembly and assembly...0
    General information on disassembly and assembly...18847
      How to read this manual...18848
      Coating materials list...18850
      Special tools list...18853
      Sketches of special tools...18856
    Engine and cooling system...18863
      Removal and installation of fuel supply pump assembly...18864
      Removal and installation of fuel injector assembly...18868
      Removal and installation of cylinder head assembly...18882
      Removal and installation of engine hood assembly...18904
      Removal and installation of radiator assembly...18909
      Removal and installation of air aftercooler...18914
      Removal and installation of hydraulic oil cooler assembly...18916
      Removal and installation of engine assembly...18918
      Removal and installation of engine front oil seal assembly...18923
      Removal and installation of engine rear oil seal assembly...18927
      Removal and installation of cooling fan and fan motor assembly...18930
      Removal and installation of fuel tank assembly...18936
    Power train...18939
      Removal and installation of torque converter and transmission assembly...18940
      Disassembly and assembly of torque converter assembly (Standard specification)...18946
      Disassembly and assembly of torque converter assembly (Lockup specification)...18950
      Disassembly and assembly of transmission assembly...18956
      Disassembly and assembly of transmission clutch pack assembly...18973
      Disassembly and assembly of parking brake assembly...18992
      Removal and installation of front axle assembly...19001
      Removal and installation of rear axle assembly...19003
      Disassembly and assembly of axle housing...19006
      Disassembly and assembly of differential assembly...19015
    Steering system...19035
      Removal and installation of steering valve assembly...19036
    Brake system...19041
      Removal and installation of parking brake discs and plates...19042
    Undercarriage and frame...19047
      Removal and installation of center hinge pin...19048
      Removal and installation of counterweight...19056
    Hydraulic system...19061
      Removal and installation of work equipment control valve assembly...19062
      Removal and installation of power train pump and work equipment pump assembly...19068
      Removal and installation of steering pump and cooling fan pump assembly...19069
      Removal and installation of hydraulic tank assembly...19071
    Work equipment...19075
      Removal and installation of work equipment assembly...19076
      Disassembly and assembly of hydraulic cylinder assembly...19080
    Cab and its attachments...19089
      Removal and installation of operator's cab and floor frame assembly...19090
      Removal and installation of operator's cab glass (stuck glass)...19094
      Disassembly and assembly of operator's seat assembly (Standard specification)...19102
      Removal and installation of air conditioner unit assembly...19144
    Electrical system...19149
      Removal and installation of engine controller assembly...19150
  90 Diagrams and drawings...0
    Hydraulic diagrams and drawings...19153
      Power train hydraulic circuit diagram...19154
      Automatic greasing circuit diagram...19156
      Hydraulic circuit diagram (WA380-6)...19159
      Hydraulic circuit diagram (WA380Z-6)...19160
    Electrical diagrams and drawings...19163
      Electrical circuit diagram (WA380-6)...19165
      Electrical circuit diagram (WA380Z-6)...19179
      Work equipment controller system electrical circuit diagram (WA380-6)...19188
      Connector list and stereogram (WA380-6)...19189
      Connector list and stereogram (WA380Z-6)...19190
SEN06411-02 - Wheel Loader WA380-6, WA380Z-6 Shop Manual...19193
  Cover...19193
  00 Index and foreword...0
    Index...19195
      Composition of shop manual...19196
      Table of contents...19198
    Foreword and general information...19211
      Safety notice...19212
      How to read the shop manual...19217
      Explanation of terms for maintenance standard...19219
      Handling of electric equipment and hydraulic component...19221
      Handling of connectors newly used for engines...19230
      How to read electric wire code...19233
      Precautions when carrying out operation...19236
      Method of disassembling and connecting push-pull type coupler...19239
      Standard tightening torque table...19242
      Conversion table...19246
  01 Specification...19253
    Specification and technical data...0
      Specification dimension drawing...19254
      Specifications...19256
      Weight table...19264
      Table of fuel, coolant and lubricants...19268
  10 Structure, function and maintenance standard...0
    Engine and cooling system...19271
      Engine mount and transmission mount...19272
      Cooling system...19273
      Cooling fan pump...19275
      Brake and fan pump...19282
      Cooling fan motor...19283
    Power train...19297
      Power train...19299
      Power train system diagram...19300
      Drive shaft...19303
      Power train piping diagram...19304
      Torque converter...19306
      Transmission...19314
      Flow control valve...19348
      Valve assembly...19350
      ECMV...19351
      Main relief valve and torque converter relief valve...19359
      Differential...19363
      Limited slip differential...19367
      Final drive...19374
    Steering system...19379
      Steering piping diagram...19380
      Steering column...19382
      Steering pump...19384
      Steering valve...19404
      Orbit-roll valve...19419
      Stop valve...19427
      Steering relief valve...19428
      Steering cylinder...19429
      Emergency steering motor...19431
      Emergency steering pump...19432
      Joystick steering lever linkage...19433
      Steering electric lever...19434
      Joystick EPC valve...19435
    Brake system...19437
      Brake piping diagram...19438
      Charge valve...19440
      Brake valve...19447
      Accumulator (for brake)...19452
      Brake...19454
      Parking brake control...19459
      Parking brake...19460
      Parking brake solenoid valve...19462
      Emergency parking brake release valve...19464
    Undercarriage and frame...19467
      Axle mount and center hinge pin...19468
      Tires...19473
    Hydraulic system, Part 1...19475
      Hydraulic piping diagram...19476
      Work equipment control lever linkage...19482
      Hydraulic tank...19485
      Power train pump...19489
      Work equipment pump...19490
      Work equipment control valve...19512
      CLSS...19540
      Each function and operation of each valve...19544
    Hydraulic system, Part 2...19577
      PPC valve...19578
      Stabilizer valve...19584
      Accumulator (for PPC circuit)...19590
      Accumulator (for ECSS)...19591
      Work equipment PPC cut-off solenoid valve...19592
    Work equipment...19595
      Work equipment linkage...19596
      Bucket...19600
      Bucket positioner and boom kick-out...19602
      Work equipment cylinder...19608
    Cab and its attachments...19611
      Cab...19613
      Air conditioner...19614
    Electrical system, Part 1...19635
      Machine monitor system...19636
      Machine monitor...19644
    Electrical system, Part 2...19703
      Electrical system (Transmission controller system)...19704
      Transmission controller...19748
      Electrical system (Work equipment controller system)...19752
      Work equipment controller...19758
    Electrical system, Part 3...19761
      Electric transmission control...19762
      Kickdown switch and hold switch...19766
      Multi-function knob...19768
      Joystick steering knob...19769
      KOMTRAX terminal system...19770
      Engine starting circuit...19772
      Engine stopping circuit...19776
      Preheating circuit...19778
      Engine power mode selector circuit...19779
      Engine output derating function...19780
      Automatic warm-up function...19780
      Parking brake circuit...19782
      Sensor...19784
  20 Standard value table...0
    Standard service value table...19795
      Standard service value table for engine...19796
      Standard service value table for chassis...19798
  30 Testing and adjusting...0
    Testing and adjusting, Part 1...19811
      Tools for testing, adjusting, and troubleshooting...19813
      Testing engine speed...19820
      Testing exhaust gas color...19822
      Adjusting valve clearance...19824
      Testing compression pressure...19829
      Testing blow-by pressure...19835
      Testing engine oil pressure...19836
      Testing intake air (boost) pressure...19838
      Handling fuel system equipment...19840
      Releasing residual pressure in fuel system...19840
      Testing fuel pressure...19841
      Testing fuel delivery, return and leak amount...19846
      Bleeding air from fuel circuit...19854
      Testing leakage in fuel system...19856
      Handling reduced cylinder mode operation...19857
      Handling no-injection cranking operation...19857
      Handling controller voltage circuit...19858
      Testing muffler (main body) and muffler stack for looseness or damage...19858
      Testing muffler for functions...19859
      Testing cylinder head and manifold parts for tightness...19859
      Testing engine piping for damage and tightness...19860
      Testing and adjusting air conditioner compressor belt tension...19861
      Replacing alternator belt...19862
      Adjusting transmission speed sensor...19863
      Adjusting length of directional lever...19864
      Adjusting length of gearshift lever...19864
      Testing directional lever...19865
      Testing and adjusting power train oil pressure...19866
      Procedure for flushing torque converter and transmission hydraulic circuit...19895
      Method of moving machine when transmission valve is broken...19896
      Testing axle end for oil leakage...19900
      Testing drive shaft for looseness, backlash and damage...19900
      Testing and adjusting steering stop valve...19901
      Testing and adjusting steering wheel...19903
      Testing and adjusting steering oil pressure...19905
      Bleeding air from steering circuit...19908
    Testing and adjusting, Part 2...19911
      Testing hydraulic drive fan...19913
      Bleeding air from hydraulic drive fan circuit...19917
      Testing brake pedal...19920
      Testing and adjusting brake pedal linkage...19921
      Testing brake performance...19922
      Testing and adjusting accumulator charge pressure...19923
      Testing wheel brake oil pressure...19925
      Testing wheel brake oil pressure drop...19926
      Testing wear of wheel brake disc...19928
      Bleeding air from wheel brake circuit...19929
      Releasing residual pressure in brake accumulator circuit...19930
      Testing parking brake performance...19931
      Testing parking brake oil pressure...19932
      Testing wear of parking brake disc...19934
      Method of releasing parking brake manually...19935
      Testing and adjusting work equipment control lever...19936
      Testing and adjusting worke quipment PPC oil pressure...19937
      Testing and adjusting work equipment oil pressure...19943
      Bleeding air from work equipment circuit...19947
      Releasing residual pressure in work equipment circuit...19948
      Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator...19950
      Testing and adjusting bucket positioner...19956
      Testing and adjusting boom kick-out...19958
      Checking proximity switch operation pilot lamp...19959
      Procedure for testing diodes...19960
      Preparation work for troubleshooting for electric system...19961
      How to start operation of KOMTRAX terminal...19970
      Lamp display of KOMTRAX terminal...19975
    Testing and adjusting, Part 3...19979
      Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor...19981
      Special functions of machine monitor (EMMS)...19983
      Pm-clinic inspection table...20052
  40 Troubleshooting...0
    Failure code table and fuse locations...20059
      Failure code table...20060
      Fuse locations...20077
    General information on troubleshooting...20083
      Points to remember when troubleshooting...20084
      Sequence of events in troubleshooting...20085
      Testing before troubleshooting...20087
      Classification and procedures of troubleshooting...20088
      Information contained in troubleshooting table...20091
      Connection table for connector pin numbers...20093
      T- branch box and T- branch adapter table...20129
    Troubleshooting by failure code (Display of code), Part 1...20133
      Failure code [1500L0] (TORQFLOW transmission: Double meshing)...20135
      Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)...20136
      Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)...20138
      Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)...20140
      Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)...20142
      Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)...20144
      Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)...20146
      Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)...20148
      Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)...20150
      Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)...20152
      Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)...20154
      Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)...20156
      Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)...20158
      Failure code [2F00MA] (Parking brake: Malfunction)...20160
      Failure code [2G43ZG] (Accumulator: Low oil pressure)...20163
      Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)...20167
    Troubleshooting by failure code (Display of code), Part 2...20171
      Failure code [AA1ANX] (Air cleaner: Clogging)...20174
      Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)...20177
      Failure code [AB00MA] (Alternator: Malfunction)...20181
      Failure code [B@BAZG] (Rotation derating by low engine oil pressure)...20185
      Failure code [B@BAZK] (Engine oil: Low level)...20186
      Failure code [B@BCNS] (Coolant: Overheating)...20187
      Failure code [B@BCZK] (Coolant: Low level)...20189
      Failure code [B@BEBF] (Water in fuel error)...20192
      Failure code [B@C7NS] (Brake oil: Overheating)...20194
      Failure code [b@CENS] (Torque converter oil: Overheating)...20196
      Failure code [B@CENS] (Torque converter oil: Overheating)...20199
      Failure code [B@HANS] (Hydraulic oil: Overheating)...20202
      Failure code [CA111] (Abnormality in engine controller)...20204
      Failure code [CA115] (Engine Ne or Bkup speed sensor error)...20205
      Failure code [CA122] (Charge pressure sensor high error)...20206
      Failure code [CA123] (Charge pressure sensor low error)...20208
      Failure code [CA131] (Throttle sensor high error)...20210
      Failure code [CA132] (Throttle sensor low error)...20212
      Failure code [CA144] (Coolant sensor high error)...20214
      Failure code [CA145] (Coolant sensor low error)...20216
      Failure code [CA153] (Charge temperature sensor high error)...20218
      Failure code [CA154] (Charge temperature sensor low error)...20220
      Failure code [CA155] (Derating of speed by abnormally high charge temperature)...20222
      Failure code [CA187] (Sensor power supply 2 low error)...20224
      Failure code [CA221] (Atmospheric pressure sensor high error)...20226
      Failure code [CA222] (Atmospheric sensor low error)...20228
      Failure code [CA227] (Sensor power supply 2 high error)...20230
      Failure code [CA234] (Engine overspeed)...20231
      Failure code [CA238] (Ne speed sensor power supply error)...20232
    Troubleshooting by failure code (Display of code), Part 3...20235
      Failure code [CA271] (IMV/PCV1 Short circuit)...20237
      Failure code [CA272] (IMV/PCV1 Disconnection)...20238
      Failure code [CA322] (Injector #1 open/short error)...20240
      Failure code [CA323] (Injector #5 open/short error)...20242
      Failure code [CA324] (Injector #3 open/short error)...20244
      Failure code [CA325] (Injector #6 open/short error)...20246
      Failure code [CA331] (Injector #2 open/short error)...20248
      Failure code [CA332] (Injector #4 open/short error)...20250
      Failure code [CA342] (Calibration code inconsistency)...20252
      Failure code [CA351] (Injectors drive circuit error)...20254
      Failure code [CA352] (Sensor power supply 1 low error)...20257
      Failure code [CA386] (Sensor power supply 1 high error)...20259
      Failure code [CA428] (Abnormally high level in water sensor)...20260
      Failure code [CA429] (Abnormally low level in water sensor)...20261
      Failure code [CA431] (Idle validation switch error)...20262
      Failure code [CA432] (Idle validation action error)...20265
      Failure code [CA435] (Engine oil pressure switch error)...20267
      Failure code [CA441] (Battery voltage low error)...20268
      Failure code [CA442] (Battery voltage high error)...20272
      Failure code [CA449] Common rail pressure high error 2...20275
      Failure code [CA451] (Common rail pressure sensor high error)...20277
      Failure code [CA452] (Common rail pressure sensor low error)...20279
      Failure code [CA488] (Derating of torque by abnormally high charge temperature)...20281
      Failure code [CA553] (Common rail pressure high error 1)...20282
      Failure code [CA559] (Supply pump pressure very low error)...20283
      Failure code [CA689] (Engine Ne speed sensor error)...20284
      Failure code [CA731] (Engine Bkup speed sensor phase error)...20287
      Failure code [CA757] (All continuous data lost error)...20288
      Failure code [CA778] (Engine Bkup speed sensor error)...20292
      Failure code [CA1633] (KOMNET datalink timeout error)...20295
      Failure code [CA2185] (Throttle sensor power supply voltage high error)...20298
      Failure code [CA2186] (Throttle sensor power supply voltage low error)...20299
    Troubleshooting by failure code (Display of code), Part 4...20301
      Failure code [CA2249] (Supply pump pressure very low error 2)...20303
      Failure code [CA2311] (Abnormality in IMV solenoid)...20304
      Failure code [CA2555] (Intake heater relay disconnection error)...20306
      Failure code [CA2556] (Intake heater relay short circuit error)...20309
      Failure code [D150KA] (Emergency steering relay: Disconnection)...20312
      Failure code [D150KB] (Emergency steering relay: Short circuit)...20315
      Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)...20318
      Failure code [D160KA] (Backup lamp relay: Disconnection)...20321
      Failure code [D160KB] (Backup lamp relay: Short circuit)...20324
      Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)...20327
      Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)...20329
      Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)...20331
      Failure code [D192KA] (ECSS solenoid: Disconnection)...20333
      Failure code [D192KB] (ECSS solenoid: Short circuit)...20334
      Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)...20335
      Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection)...20336
      Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit)...20338
      Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line)...20340
      Failure code [D5ZHKA] (Terminal C signal: Disconnection)...20343
      Failure code [D5ZHKB] (Terminal C signal: Short circuit)...20349
      Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)...20354
      Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)...20361
      Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)...20366
      Failure code [DAF3KK] (Machine monitor: Low source voltage (input)...20368
      Failure code [DAF5KP] (Machine monitor: Low output voltage)...20372
      Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system)...20376
    Troubleshooting by failure code (Display of code), Part 5...20381
      Failure code [DAQ0KK] (Transmission controller: Low source voltage)...20384
      Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)...20388
      Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)...20389
      Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)...20392
      Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)...20393
      Failure code [DAQRMA] (Transmission controller option setting: Malfunction)...20399
      Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)...20400
      Failure code [DB90KK] Work equipment controller: Low source voltage (input)...20404
      Failure code [DB90KT] Work equipment controller: Abnormality in controller...20406
      Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)...20407
      Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range...20409
      Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)...20412
      Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)...20413
      Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)...20415
      Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation)...20416
      Failure code [DD15LD] ■ switch (Panel switch 1): Switch is kept pressed for long time...20420
      Failure code [DD16LD] <> switch (Panel switch 2): Switch is kept pressed for long time...20423
      Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time...20426
      Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time...20429
      Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time...20432
      Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time...20434
      Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time...20436
      Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time...20438
      Failure code [DD1GLD] Load meter mode selector switch (+/-): Switch is kept pressed for long time...20440
      Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)...20442
      Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)...20444
      Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)...20446
      Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)...20448
    Troubleshooting by failure code (Display of code), Part 6...20453
      Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)...20456
      Failure code [DDK3KA] (Right FNR switch: Disconnection)...20459
      Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)...20462
      Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)...20465
      Failure code [DDK6KA] (FNR lever switch: Disconnection)...20467
      Failure code [DDK6KB] (FNR lever switch: Short circuit)...20474
      Failure code [DDS5KA] (Steering pressure switch: Disconnected)...20478
      Failure code [DDS5KB] (Steering pressure switch: Grounded)...20480
      Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)...20482
      Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)...20485
      Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)...20488
      Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)...20491
      Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)...20494
      Failure code [DF10KA] (Transmission shift lever switch: Disconnected)...20496
      Failure code [DF10KB] (Transmission shift lever switch: Short circuit)...20500
      Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)...20503
      Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)...20506
      Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)...20509
      Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)...20511
      Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)...20513
      Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)...20515
      Failure code [DH21KA] (Loader pump pressure sensor: Disconnection)...20518
      Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short)...20520
    Troubleshooting by failure code (Display of code), Part 7...20523
      Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)...20526
      Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)...20528
      Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)...20530
      Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)...20534
      Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)...20536
      Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)...20538
      Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)...20541
      Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)...20544
      Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)...20547
      Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)...20550
      Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)...20553
      Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)...20556
      Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)...20559
      Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)...20562
      Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)...20565
    Troubleshooting by failure code (Display of code), Part 8...20569
      Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)...20571
      Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)...20574
      Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)...20576
      Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)...20580
      Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)...20582
      Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)...20586
      Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)...20588
      Failure code [DKA0L0] (Lift arm angle sensor: Dislocation of sensor)...20590
      Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)...20592
      Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)...20594
      Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)...20596
      Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)...20600
      Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)...20602
      Failure code [DV00KB] (Alarm buzzer: Short circuit)...20604
      Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)...20606
      Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)...20608
      Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)...20610
      Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)...20612
      Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)...20613
      Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)...20614
      Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)...20616
      Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)...20617
      Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)...20618
    Troubleshooting by failure code (Display of code), Part 9...20621
      Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)...20623
      Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)...20624
      Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)...20626
      Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)...20628
      Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)...20630
      Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)...20632
      Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)...20634
      Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)...20636
      Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)...20638
      Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)...20640
      Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)...20642
      Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)...20644
      Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)...20646
      Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)...20648
      Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)...20650
      Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)...20652
      Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)...20654
      Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)...20656
      Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) (WA380-6)...20658
      Failure code [DX16KA] (Fan motor EPC solenoid: Disconnection) (WA380Z-6)...20659
      Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) (WA380-6)...20660
      Failure code [DX16KB] (Fan motor EPC solenoid: Short circuit) (WA380Z-6)...20661
      Failure code [DX16KY] (Fan motor EPC solenoid: Short circuit with power supply line) (WA380Z-6)...20663
      Failure code [DXA1KA] (Loader pump EPC solenoid: Disconnection)...20664
      Failure code [DXA1KB] (Loader pump EPC solenoid: Short circuit)...20666
      Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)...20668
      Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)...20670
      Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)...20672
      Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)...20674
      Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)...20676
      Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)...20678
    Troubleshooting by failure code (Display of code), Part 10...20681
      Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)...20684
      Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)...20686
      Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)...20688
      Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)...20690
      Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)...20692
      Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)...20694
      Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)...20696
      Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)...20698
      Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)...20700
      Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)...20702
      Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)...20704
      Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)...20706
      Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)...20708
      Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)...20710
      Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)...20712
      Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)...20714
      Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)...20716
      Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)...20718
      Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)...20720
      Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)...20722
      Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)...20724
      Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine)...20726
      Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode)...20731
    Troubleshooting of electrical system (E-mode)...20739
      Installing positions of fuses...20741
      Information in troubleshooting table...20746
      E-1 Engine does not start...20747
      E-2 Wiper does not operate...20760
      E-3 Windshield washer does not operate...20765
      E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off...20769
      E-5 Working lamp does not light up or go off...20785
      E-6 Turn signal lamp and hazard lamp do not light up or go off...20795
      E-7 Brake lamp does not light or it keeps lighting up...20807
      E-8 Backup lamp does not light or it keeps lighting up...20811
      E-9 Backup buzzer does not sound or it keeps sounding...20815
      E-10 Horn does not sound or it keeps sounding...20818
      E-11 Alarm buzzer does not sound or it keeps sounding...20822
      E-12 Air conditioner does not operate or stop...20824
      E-13 The KOMTRAX system does not work properly...20828
      E-14 When kick-down switch is turned ON, kick-down operation does not start...20831
      E-15 When hold switch is pressed, holding operation does not start...20834
      E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied...20837
      E-17 Transmission cut-off mode cannot be set or reset...20840
      E-18 Transmission cut-off set cannot be reset...20843
      E-19 FNR switch mode cannot be set or reset...20846
      E-20 Fan reverse function cannot be used or reset...20848
      E-21 Discharge from loader pump does not rise from minimum level...20850
      E-22 ECSS function cannot be used or reset...20852
      E-23 When parking brake is turned ON, parking brake indicator lamp does not light up...20854
      E-24 When emergency brake operates, brake oil pressure caution lamp does not operate...20858
      E-25 Air cleaner clogging indicator lamp does not light up...20862
      E-26 Radiator coolant level caution lamp does not light up...20865
      E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light up...20867
      E-28 Torque converter oil temperature gauge does not rise and torque converter oil temperature caution lamp does not light up...20869
      E-29 Steering oil pressure caution lamp does not light up...20871
      E-30 Abnormality in ■ switch (panel switch 1) input...20874
      E-31 Abnormality in <> switch (panel switch 2) input...20877
      名称未設定...20880
      E-32 Abnormality in < switch (panel switch 3) input...20880
      E-33 Abnormality in > switch (panel switch 4) input...20883
    Troubleshooting of hydraulic and mechanical system (H-mode)...20887
      Method of using troubleshooting chart...20889
      Table of failure modes and causes...20892
      H-1 The machine does not start...20900
      H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch]...20902
      H-3 Torque converter lockup is not switched on [Machine with lockup clutch]...20903
      H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted...20904
      H-5 Shocks are large at the times of starting and shifting gear...20906
      H-6 Time lag is large at the times of starting and shifting gear...20908
      H-7 The torque converter oil temperature is high...20910
      H-8 Steering does not turn...20911
      H-9 Steering does not turn [Machine with joystick steering]...20912
      H-10 Steering response is low...20913
      H-11 Turning, response of steering is poor [machine with joystick steering]...20914
      H-12 Steering is heavy...20915
      H-13 When machine turns, it shakes or makes large shocks...20916
      H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering]...20917
      H-15 The wheel brake does not work or does not work well...20918
      H-16 The wheel brake is not released or it drags...20919
      H-17 The parking brake does not work or does not work well...20920
      H-18 The parking brake is not released or it drags (including emergency release system)...20921
      H-19 Lift arm does not rise...20922
      H-20 Lift arm speed is low or rising force of lift arm is insufficient...20923
      H-21 When rising, the lift arm comes to move slowly at specific height...20924
      H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)...20924
      H-23 Hydraulic drifts of the lift arm is large...20924
      H-24 The lift arm wobbles during operation...20924
      H-25 Bucket does not tilt back...20925
      H-26 Bucket speed is low or tilting back force is insufficient...20926
      H-27 The bucket comes to operate slowly in the midst of tilting-back...20927
      H-28 The bucket cylinder cannot hold down the bucket...20927
      H-29 Hydraulic drifts of the bucket is large...20927
      H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”)...20927
      H-31 Lift arm and bucket control levers do not move smoothly and are heavy...20928
      H-32 During operation of the machine, engine speed lowers remarkably or engine stalls...20929
      H-33 Large shock is made when work equipment starts and stops...20929
      H-34 When work equipment circuit is relieved singly, other work equipment moves...20929
      H-35 ECSS does not operate, and pitching, bouncing occur...20930
      H-36 Fan revolution is abnormal (Fan sound/ vibration is abnormally large or engine overheats)...20931
    Troubleshooting of engine (S-mode)...20933
      Method of using troubleshooting charts...20935
      S-1 Engine does not start easily...20938
      S-2 Engine does not start...20939
      S-3 Engine does not pick up smoothly...20942
      S-4 Engine stops during operations...20943
      S-5 Engine does not rotate smoothly...20944
      S-6 Engine lacks output (or lacks power)...20945
      S-7 Exhaust smoke is black (Incomplete combustion)...20946
      S-8 Oil consumption is excessive (or exhaust smoke is blue)...20947
      S-9 Engine oil becomes contaminated quickly...20948
      S-10 Fuel consumption is excessive...20949
      S-11 Coolant contains oil (blows back or reduces)...20950
      S-12 Oil pressure drops...20951
      S-13 Oil level rises (Water, fuel in oil)...20952
      S-14 Coolant temperature rises too high (Overheating)...20953
      S-15 Abnormal noise is made...20954
      S-16 Vibration is excessive...20955
  50 Disassembly and assembly...0
    General information on disassembly and assembly...20957
      How to read this manual...20958
      Coating materials list...20960
      Special tools list...20963
      Sketches of special tools...20966
    Engine and cooling system...20973
      Removal and installation of fuel supply pump assembly...20974
      Removal and installation of fuel injector assembly...20978
      Removal and installation of cylinder head assembly...20992
      Removal and installation of engine hood assembly...21014
      Removal and installation of radiator assembly...21019
      Removal and installation of air aftercooler...21024
      Removal and installation of hydraulic oil cooler assembly...21026
      Removal and installation of engine assembly...21028
      Removal and installation of engine front oil seal assembly...21033
      Removal and installation of engine rear oil seal assembly...21037
      Removal and installation of cooling fan and fan motor assembly...21040
      Removal and installation of fuel tank assembly...21046
    Power train...21049
      Removal and installation of torque converter and transmission assembly...21050
      Disassembly and assembly of torque converter assembly (Standard specification)...21056
      Disassembly and assembly of torque converter assembly (Lockup specification)...21060
      Disassembly and assembly of transmission assembly...21066
      Disassembly and assembly of transmission clutch pack assembly...21083
      Disassembly and assembly of parking brake assembly...21102
      Removal and installation of front axle assembly...21111
      Removal and installation of rear axle assembly...21113
      Disassembly and assembly of axle housing...21116
      Disassembly and assembly of differential assembly...21125
    Steering system...21145
      Removal and installation of steering valve assembly...21146
    Brake system...21151
      Removal and installation of parking brake discs and plates...21152
    Undercarriage and frame...21157
      Removal and installation of center hinge pin...21158
      Removal and installation of counterweight...21166
    Hydraulic system...21171
      Removal and installation of work equipment control valve assembly...21172
      Removal and installation of power train pump and work equipment pump assembly...21178
      Removal and installation of steering pump and cooling fan pump assembly...21179
      Removal and installation of hydraulic tank assembly...21181
    Work equipment...21185
      Removal and installation of work equipment assembly...21186
      Disassembly and assembly of hydraulic cylinder assembly...21190
    Cab and its attachments...21199
      Removal and installation of operator's cab and floor frame assembly...21200
      Removal and installation of operator's cab glass (stuck glass)...21204
      Disassembly and assembly of operator's seat assembly (Standard specification)...21212
      Removal and installation of air conditioner unit assembly...21254
    Electrical system...21259
      Removal and installation of engine controller assembly...21260
  90 Diagrams and drawings...0
    Hydraulic diagrams and drawings...21263
      Power train hydraulic circuit diagram...21264
      Automatic greasing circuit diagram...21266
      Hydraulic circuit diagram (WA380-6)...21269
      Hydraulic circuit diagram (WA380Z-6)...21270
    Electrical diagrams and drawings...21273
      Electrical circuit diagram...21275
      Work equipment controller system electrical circuit diagram...21298
      Connector list and stereogram...21299
SEN06573 - Wheel Loader WA380-8 Shop Manual...21303
  COVER...21303
  00 INDEX AND FOREWORD...21305
    INDEX...21306
    ABBREVIATION LIST...21326
    FOREWORD, SAFETY, BASIC INFORMATION...21332
      HOW TO READ THE SHOP MANUAL...21332
      SAFETY NOTICE FOR OPERATION...21334
      PRECAUTIONS TO PREVENT FIRE...21342
      ACTIONS IF FIRE OCCURS...21344
      PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS...21345
      ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...21346
      PRECAUTIONS FOR DEF...21347
        GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING...21347
        PRECAUTIONS FOR ADDING...21347
        PRECAUTIONS FOR STORING...21347
        PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE...21347
        THE OTHER PRECAUTIONS...21347
      STORE AdBlue/DEF...21348
      PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT...21349
      PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS...21352
      PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT...21358
      PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT...21360
      PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT...21361
      PRACTICAL USE OF KOMTRAX...21362
      DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER...21363
        METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER...21363
        METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER...21364
        METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER...21365
      PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...21367
      METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR...21371
      METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR...21372
      METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL...21374
      METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH...21375
      METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE...21377
      HOW TO READ ELECTRICAL WIRE CODE...21378
      EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...21382
      STANDARD TIGHTENING TORQUE TABLE...21385
      CONVERSION TABLE...21392
  01 SPECIFICATIONS...21397
    CONTENTS...21398
    ABBREVIATION LIST...21399
    SPECIFICATIONS...21405
      SPECIFICATION DRAWING...21405
        SPECIFICATION DRAWING: WA380-8...21405
      SPECIFICATIONS...21407
        SPECIFICATIONS: WA380-8...21407
      WEIGHT TABLE...21412
        WEIGHT TABLE: WA380-8...21412
      TABLE OF FUEL, COOLANT, AND LUBRICANTS...21414
  10 STRUCTURE AND FUNCTION...21417
    CONTENTS...21418
    ABBREVIATION LIST...21423
    UREA SCR SYSTEM...21429
      LAYOUT DRAWING OF UREA SCR SYSTEM...21429
      UREA SCR SYSTEM DIAGRAM...21433
      FUNCTION OF UREA SCR SYSTEM...21434
        FUNCTION OF AdBlue/DEF SYSTEM...21434
        INDUCEMENT STRATEGY...21437
      COMPONENT PARTS OF UREA SCR SYSTEM...21452
        AdBlue/DEF MIXING TUBE...21452
        SCR ASSEMBLY...21453
        AdBlue/DEF TANK...21455
        AdBlue/DEF PUMP...21457
        AdBlue/DEF INJECTOR...21458
        AdBlue/DEF HOSE...21459
        AdBlue/DEF TANK HEATING VALVE...21460
    BOOT-UP SYSTEM...21461
      LAYOUT DRAWING OF BOOT-UP SYSTEM...21461
      SYSTEM OPERATING LAMP SYSTEM...21462
        SYSTEM OPERATING LAMP SYSTEM DIAGRAM...21462
        FUNCTION OF SYSTEM OPERATING LAMP SYSTEM...21462
      BATTERY DISCONNECT SWITCH...21463
        LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH...21463
        FUNCTION OF BATTERY DISCONNECT SWITCH...21463
      PREHEATING SYSTEM...21465
        PREHEATING SYSTEM DIAGRAM...21465
        FUNCTION OF AUTOMATIC PREHEATING SYSTEM...21465
        OPERATION OF AUTOMATIC PREHEATING SYSTEM...21465
        FUNCTION OF MANUAL PREHEATING SYSTEM...21466
        OPERATION OF MANUAL PREHEATING SYSTEM...21466
    ENGINE SYSTEM...21467
      LAYOUT DRAWING OF ENGINE SYSTEM...21467
        FUNCTION OF ENGINE SYSTEM...21468
      ENGINE CONTROL SYSTEM...21469
        ENGINE CONTROL SYSTEM DIAGRAM...21469
        FUNCTION OF ENGINE CONTROL SYSTEM...21470
        OPERATION OF ENGINE CONTROL SYSTEM...21473
      ENGINE POWER MODE SELECTOR SYSTEM...21475
        ENGINE POWER MODE SELECTOR SYSTEM DIAGRAM...21475
        FUNCTION OF ENGINE POWER MODE SELECTOR SYSTEM...21475
        OPERATION OF ENGINE POWER MODE SELECTOR SYSTEM...21475
      AUTOMATIC IDLE STOP SYSTEM...21477
        FUNCTION OF AUTOMATIC IDLE STOP SYSTEM...21477
      COMPONENT PARTS OF ENGINE SYSTEM...21478
        VGT...21478
        EGR SYSTEM...21482
        EGR VALVE...21484
        EGR COOLER...21486
        KCCV SYSTEM...21488
        KCCV VENTILATOR...21490
        KDPF...21492
    COOLING SYSTEM...21496
      LAYOUT DRAWING OF COOLING SYSTEM...21496
        SPECIFICATIONS OF COOLING SYSTEM...21497
      COOLING FAN CONTROL SYSTEM...21499
        COOLING FAN CONTROL SYSTEM DIAGRAM...21499
        FUNCTION OF COOLING FAN CONTROL SYSTEM...21499
      COMPONENT PARTS OF COOLING SYSTEM...21504
        BRAKE AND COOLING FAN PUMP...21504
        COOLING FAN MOTOR...21512
    CONTROL SYSTEM...21518
      LAYOUT DRAWING OF CONTROL SYSTEM...21518
      MACHINE MONITOR SYSTEM...21520
        MACHINE MONITOR SYSTEM DIAGRAM...21520
        FUNCTION OF MACHINE MONITOR SYSTEM...21520
      REARVIEW MONITOR SYSTEM...21522
        REARVIEW MONITOR SYSTEM DIAGRAM...21522
        FUNCTION OF REARVIEW MONITOR SYSTEM...21522
      KOMTRAX SYSTEM...21523
        KOMTRAX SYSTEM DIAGRAM...21523
        FUNCTION OF KOMTRAX SYSTEM...21523
      COMPONENT PARTS OF CONTROL SYSTEM...21524
        MACHINE MONITOR...21524
        SWITCH PANEL...21544
        REARVIEW MONITOR...21545
        REARVIEW CAMERA...21547
        KOMTRAX TERMINAL...21548
        TRANSMISSION CONTROLLER...21550
        WORK EQUIPMENT CONTROLLER...21554
        MONITOR CONTROLLER...21558
        CAN TERMINATING RESISTOR...21563
        ENGINE CONTROLLER...21564
        ACCELERATOR PEDAL...21571
    HYDRAULIC SYSTEM...21573
      LAYOUT DRAWING OF HYDRAULIC SYSTEM...21573
      CLSS...21574
        STRUCTURE OF CLSS...21574
        FUNCTION OF CLSS...21575
      WORK EQUIPMENT PUMP AND STEERING PUMP CONTROL SYSTEM...21577
        SWASH PLATE CONTROL FUNCTION OF WORK EQUIPMENT PUMP AND STEERING PUMP...21577
        PICKUP ASSISTANCE CONTROL FUNCTION WHEN ENGINE SPEED IS LOW...21577
        OVERHEAT PREVENTION FUNCTION OF WORK EQUIPMENT CIRCUIT...21577
      COMPONENT PARTS OF HYDRAULIC SYSTEM...21578
        HYDRAULIC TANK...21578
        WORK EQUIPMENT PUMP...21581
        STEERING PUMP...21595
        POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP...21607
        CONTROL VALVE...21608
        STABILIZER VALVE...21646
    POWER TRAIN SYSTEM...21652
      LAYOUT DRAWING OF POWER TRAIN SYSTEM...21652
      OPERATION OF POWER TRAIN SYSTEM...21655
      TRANSMISSION CONTROL SYSTEM...21656
        TRANSMISSION CONTROL SYSTEM DIAGRAM...21656
      TRANSMISSION GEAR SHIFT CONTROL SYSTEM...21658
        ELECTRIC MODULATION FUNCTION SYSTEM DIAGRAM...21658
        ELECTRIC MODULATION FUNCTION...21659
        DISPLAY FUNCTION OF GEAR SHIFT...21659
        AUTOMATIC GEAR SHIFT FUNCTION...21659
        SHIFT HOLD FUNCTION...21660
        KICKDOWN FUNCTION...21660
        AUTOMATIC KICKDOWN FUNCTION...21661
        TORQUE CONVERTER LOCKUP FUNCTION...21661
        HUNTING PREVENTION FUNCTION...21662
        ADJUSTING FUNCTION OF TRANSMISSION INITIAL LEARNING AND ECMV CURRENT...21662
        SHIFT POINT CHANGING FUNCTION...21662
        4TH GEAR SPEED LIMITATION FUNCTION...21662
      TRANSMISSION PROTECTION FUNCTION...21664
        PROTECTION FUNCTION WHEN TRAVEL DIRECTION IS CHANGED...21664
        SHIFT DOWN PROTECTION FUNCTION...21664
        ENGINE OVERRUN PREVENTION FUNCTION...21665
        MAXIMUM SPEED LIMITATION FUNCTION...21665
        NEUTRALIZER FUNCTION...21665
      DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION...21667
      TRANSMISSION CUT-OFF FUNCTION...21669
      COMPONENT PARTS OF POWER TRAIN SYSTEM...21671
        DRIVE SHAFT...21671
        TORQUE CONVERTER...21673
        LOCKUP CLUTCH ECMV...21676
        TRANSMISSION...21679
        TRANSMISSION CONTROL VALVE...21695
        FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV...21697
        MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE...21702
        AXLE...21704
        CONVENTIONAL DIFFERENTIAL...21707
        LIMITED SLIP DIFFERENTIAL...21710
        FINAL DRIVE...21714
        COMBINATION SWITCH...21716
        SHIFT HOLD SWITCH...21720
        KICKDOWN SWITCH...21721
    WORK EQUIPMENT SYSTEM...21722
      LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM...21722
      WORK EQUIPMENT SYSTEM DIAGRAM...21724
      WORK EQUIPMENT CONTROL SYSTEM...21726
        WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE...21726
        WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION...21727
        WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM...21728
        WORK EQUIPMENT LEVER OPERATION FUNCTION...21729
        BUCKET PRIORITY CONTROL FUNCTION...21729
        BOOM STOP MODULATION FUNCTION...21729
      WORK EQUIPMENT NEUTRAL LOCK SYSTEM...21731
        WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM...21731
        FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM...21731
      REMOTE POSITIONER SYSTEM...21733
        REMOTE BUCKET POSITIONER SYSTEM DIAGRAM...21733
        FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM...21733
        REMOTE BOOM POSITIONER SYSTEM DIAGRAM...21734
        FUNCTION OF REMOTE BOOM POSITIONER SYSTEM...21734
      BUCKET POSITIONER AND BOOM POSITIONER...21738
        STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER...21738
      AUTO-DIGGING SYSTEM...21739
        AUTO-DIGGING SYSTEM DIAGRAM...21739
        FUNCTION OF AUTO-DIGGING SYSTEM...21739
      SEMI AUTO-DIGGING SYSTEM...21741
        SEMI AUTO-DIGGING SYSTEM DIAGRAM...21741
        FUNCTION OF SEMI AUTO-DIGGING SYSTEM...21741
      ECSS...21743
        ECSS DIAGRAM...21743
        FUNCTION OF ECSS...21743
        OPERATION OF ECSS...21743
      COMPONENT PARTS OF WORK EQUIPMENT SYSTEM...21745
        WORK EQUIPMENT LOCK SOLENOID VALVE...21745
        PILOT CIRCUIT ACCUMULATOR...21746
        ECSS CIRCUIT ACCUMULATOR...21747
        WORK EQUIPMENT ELECTRIC LEVER...21749
        MULTIFUNCTION MONO-LEVER...21752
    STEERING SYSTEM...21753
      LAYOUT DRAWING OF STEERING SYSTEM...21753
      SECONDARY STEERING SYSTEM...21754
        SECONDARY STEERING SYSTEM DIAGRAM...21754
        FUNCTION OF SECONDARY STEERING SYSTEM...21754
      STEERING COLUMN...21756
        STRUCTURE OF STEERING COLUMN...21756
      COMPONENT PARTS OF STEERING SYSTEM...21757
        ORBITROL VALVE...21757
        STOP VALVE...21761
        STEERING VALVE...21762
        SECONDARY STEERING PUMP...21775
        SECONDARY STEERING MOTOR...21776
    BRAKE SYSTEM...21777
      LAYOUT DRAWING OF BRAKE SYSTEM...21777
        LAYOUT DRAWING OF BRAKE COOLING SYSTEM...21778
      PARKING BRAKE CONTROL SYSTEM...21779
        PARKING BRAKE CONTROL SYSTEM DIAGRAM...21779
        OPERATION OF PARKING BRAKE CONTROL SYSTEM...21779
      BRAKE COOLING CONTROL SYSTEM...21781
        BRAKE COOLING CONTROL SYSTEM DIAGRAM...21781
        FUNCTION OF BRAKE COOLING CONTROL SYSTEM...21781
      COMPONENT PARTS OF BRAKE SYSTEM...21782
        CHARGE VALVE...21782
        PARKING BRAKE SOLENOID VALVE...21788
        PARKING BRAKE EMERGENCY RELEASE VALVE...21790
        BRAKE CIRCUIT ACCUMULATOR...21791
        BRAKE VALVE...21793
        BRAKE...21797
        PARKING BRAKE...21800
        FLOW PRIORITY VALVE...21802
        BRAKE COOLING MOTOR...21804
        BRAKE COOLING PUMP...21805
        BRAKE COOLING OIL COOLER...21806
    AUTO-GREASING SYSTEM...21807
      LAYOUT DRAWING OF AUTO-GREASING SYSTEM...21807
      SPECIFICATIONS OF AUTO-GREASING SYSTEM...21808
      FUNCTION OF AUTO-GREASING SYSTEM...21810
      COMPONENT PARTS OF AUTO-GREASING SYSTEM...21811
        AUTO-GREASING PUMP...21811
    UNDERCARRIAGE AND FRAME...21812
      FRAME, AXLE MOUNT AND CENTER HINGE PIN...21812
        STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN...21812
        FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN...21813
      TIRE...21814
        FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE...21814
        STRUCTURE OF RADIAL TIRE...21814
        FUNCTION OF RADIAL TIRE...21814
        STRUCTURE OF BIAS TIRE...21815
        FUNCTION OF BIAS TIRE...21815
    WORK EQUIPMENT...21816
      STRUCTURE OF WORK EQUIPMENT...21816
      STRUCTURE OF BUCKET...21817
    CAB AND ITS ATTACHMENTS...21818
      ROPS CAB...21818
        STRUCTURE OF ROPS CAB...21818
        FUNCTION OF ROPS CAB...21818
  20 STANDARD VALUE TABLE...21819
    CONTENTS...21820
    ABBREVIATION LIST...21821
    STANDARD VALUE TABLE FOR ENGINE...21827
      STANDARD VALUE TABLE FOR ENGINE: WA380-8...21827
    STANDARD VALUE TABLE FOR MACHINE...21831
      STANDARD VALUE TABLE FOR MACHINE: WA380-8...21831
      MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE...21850
    STANDARD VALUE TABLE FOR ELECTRICAL...21853
      STANDARD VALUE TABLE FOR ELECTRICITY...21853
  30 TESTING AND ADJUSTING...21875
    CONTENTS...21876
    ABBREVIATION LIST...21880
    RELATED INFORMATION ON TESTING AND ADJUSTING...21886
      TOOLS FOR TESTING AND ADJUSTING...21886
      SKETCH OF TOOLS FOR TESTING AND ADJUSTING...21895
    ENGINE AND COOLING SYSTEM...21896
      TEST ENGINE SPEED...21896
        METHOD FOR TESTING ENGINE SPEED...21896
      TEST BOOST PRESSURE...21902
        METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR...21902
        METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL...21903
      TEST EXHAUST GAS TEMPERATURE...21906
        METHOD FOR TESTING EXHAUST GAS TEMPERATURE...21906
      TEST EXHAUST GAS COLOR...21908
        METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER...21908
        METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER...21909
      TEST AND ADJUST VALVE CLEARANCE...21911
        METHOD FOR TESTING VALVE CLEARANCE...21911
        METHOD FOR ADJUSTING VALVE CLEARANCE...21912
      TEST COMPRESSION PRESSURE...21914
        METHOD FOR TESTING COMPRESSION PRESSURE...21914
      TEST BLOWBY PRESSURE...21919
        METHOD FOR TESTING BLOWBY PRESSURE...21919
      TEST ENGINE OIL PRESSURE...21922
        METHOD FOR TESTING ENGINE OIL PRESSURE...21922
      TEST EGR VALVE AND VGT OIL PRESSURE...21924
        METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE...21924
      TEST FUEL PRESSURE...21926
        METHOD FOR TESTING FUEL PRESSURE...21927
      TEST FUEL DISCHARGE, RETURN AND LEAKAGE...21932
        METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE...21933
      BLEED AIR FROM FUEL SYSTEM...21939
        METHOD FOR BLEEDING AIR FROM FUEL SYSTEM...21939
      TEST FUEL CIRCUIT FOR LEAKAGE...21941
        METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE...21941
      HANDLE CYLINDER CUT-OUT MODE OPERATION...21943
      HANDLE NO-INJECTION CRANKING OPERATION...21944
      TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE...21945
        METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE...21945
      TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS...21946
        METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS...21946
      TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS...21947
        METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS...21947
      TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION...21948
        METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT...21948
        METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT...21948
      TEST ALTERNATOR BELT...21950
        METHOD FOR TESTING ALTERNATOR BELT...21950
      TEST AUTOMATIC TENSIONER...21952
        METHOD FOR TESTING AUTOMATIC TENSIONER...21952
      WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER...21955
        METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER...21955
      TEST SCR RELATED FUNCTIONS...21956
        TEST AdBlue/DEF PUMP RAISED PRESSURE...21960
        TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR...21963
        TEST AdBlue/DEF LINE HEATER RELAY 1...21968
        TEST AdBlue/DEF LINE HEATER RELAY 2...21972
        TEST AdBlue/DEF PUMP HEATER RELAY...21976
        TEST AdBlue/DEF TANK HEATER VALVE...21980
        TEST SCR NOx REMOVAL EFFICIENCY...21984
      CLEAN AdBlue/DEF TANK...21988
        METHOD FOR CLEANING AdBlue/DEF TANK...21988
    POWER TRAIN...21992
      TEST AND ADJUST POWER TRAIN OIL PRESSURE...21992
        METHOD FOR TESTING POWER TRAIN OIL PRESSURE...21995
        METHOD FOR ADJUSTING POWER TRAIN OIL PRESSURE...22009
      ADJUST TRANSMISSION INPUT SPEED SENSOR...22011
        METHOD FOR ADJUSTING TRANSMISSION INPUT SPEED SENSOR...22011
      ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR...22012
        METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR...22012
      FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT...22013
        METHOD FOR FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT...22013
      MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE...22015
        METHOD FOR MOVING DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE...22015
      TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE...22017
        METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE...22017
    STEERING SYSTEM...22018
      TEST STEERING WHEEL...22018
        METHOD FOR TESTING STEERING WHEEL...22018
      TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE...22020
        METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE...22020
        METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE...22022
      BLEED AIR FROM STEERING CYLINDER CIRCUIT...22024
        METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT...22024
      TEST AND ADJUST STEERING STOP VALVE...22025
        METHOD FOR TESTING STEERING STOP VALVE...22025
        METHOD FOR ADJUSTING STEERING STOP VALVE...22025
    BRAKE SYSTEM...22026
      RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT...22026
        METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT...22026
      TEST WHEEL BRAKE OIL PRESSURE...22027
        METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE...22027
      TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE...22029
        METHOD FOR TESTING BRAKE ACCUMULATOR CHARGE PRESSURE...22029
        METHOD FOR ADJUSTING BRAKE ACCUMULATOR CHARGE PRESSURE...22030
      TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE...22031
        METHOD FOR TESTING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE...22031
        METHOD FOR CHARGING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE...22033
      TEST BRAKING PERFORMANCE...22036
        METHOD FOR TESTING BRAKING PERFORMANCE...22036
      TEST BRAKE PEDAL...22037
        METHOD FOR TESTING BRAKE PEDAL...22037
      BLEED AIR FROM BRAKE CIRCUIT...22038
        METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT...22038
      TEST AND ADJUST BRAKE PEDAL AND LINKAGE...22039
        METHOD FOR TESTING BRAKE PEDAL AND LINKAGE...22039
        METHOD FOR ADJUSTING BRAKE PEDAL AND LINKAGE...22039
      TEST LOWERING OF WHEEL BRAKE PRESSURE...22040
        METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE...22041
      TEST WEAR OF WHEEL BRAKE DISC...22043
        METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC...22043
      TEST PARKING BRAKE OIL PRESSURE...22045
        METHOD FOR TESTING PARKING BRAKE OIL PRESSURE...22045
      TEST PARKING BRAKE PERFORMANCE...22047
        METHOD FOR TESTING PARKING BRAKE PERFORMANCE...22047
      RELEASE PARKING BRAKE MANUALLY...22048
        METHOD FOR RELEASING PARKING BRAKE MANUALLY...22048
      TEST WEAR AMOUNT OF PARKING BRAKE DISC...22050
        METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC...22050
    HYDRAULIC SYSTEM...22052
      RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT...22052
        METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT...22052
      TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE...22054
        METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE...22054
        METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE...22058
      TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE...22060
        METHOD FOR TESTING WORK EQUIPMENT EPC OIL PRESSURE...22060
        METHOD FOR ADJUSTING WORK EQUIPMENT EPC OIL PRESSURE...22062
      BLEED AIR FROM WORK EQUIPMENT CIRCUIT...22063
        METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT...22063
      TEST COOLING FAN SPEED...22064
        METHOD FOR TESTING COOLING FAN SPEED...22064
      TEST COOLING FAN CIRCUIT OIL PRESSURE...22066
        METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE...22066
      BLEED AIR FROM COOLING FAN CIRCUIT...22069
        METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT...22069
      TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS...22071
        METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE...22071
        METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS...22073
    WORK EQUIPMENT...22077
      TEST AND ADJUST BUCKET POSITIONER DETECTION LEVER...22077
        METHOD FOR TESTING BUCKET POTENTIOMETER LEVER...22077
        METHOD FOR ADJUSTING BUCKET POTENTIOMETER LEVER...22077
      TEST AND ADJUST BOOM POTENTIOMETER LEVER...22079
        METHOD FOR TESTING BOOM POTENTIOMETER LEVER...22079
        METHOD FOR ADJUSTING BOOM POTENTIOMETER LEVER...22079
    CAB AND ITS ATTACHMENTS...22080
      TEST DIRECTIONAL LEVER...22080
        METHOD FOR TESTING DIRECTIONAL LEVER...22080
      TEST WORK EQUIPMENT CONTROL LEVER...22081
        METHOD FOR TESTING WORK EQUIPMENT CONTROL LEVER...22081
    ELECTRICAL SYSTEM...22084
      SET AND ADJUST EACH EQUIPMENT...22084
      SET AND OPERATE MACHINE MONITOR...22088
        OPERATOR MODE...22092
        DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN...22092
        DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN...22092
        CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)...22093
        CHECKING FUNCTION OF SERVICE METER AND ODOMETER...22094
        METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD...22094
        SERVICE MODE...22098
        METHOD FOR OPERATING SERVICE MODE...22098
        METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION...22101
        METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION...22108
        ABNORMALITY RECORD MENU...22123
        METHOD FOR CONFIRMING MAINTENANCE RECORD...22128
        METHOD FOR OPERATING MAINTENANCE MODE SETTING...22130
        METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING...22135
        DEFAULT MENU...22137
        DIAGNOSTIC TESTS MENU...22153
        ADJUSTMENT MENU...22163
        METHOD FOR PERFORMING NO-INJECTION CRANKING...22210
        KOMTRAX SETTINGS MENU...22212
        METHOD FOR DISPLAYING SERVICE MESSAGE...22214
      METHOD FOR STARTING UP KOMTRAX TERMINAL...22216
      ADJUST REARVIEW CAMERA ANGLE...22221
        METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE...22221
      HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER...22223
      HANDLE BATTERY DISCONNECT SWITCH...22224
      TEST DIODES...22225
        METHOD FOR TESTING DIODE USING DIGITAL TESTER...22225
        METHOD FOR TESTING DIODE USING ANALOG TESTER...22225
    AUTO-GREASING DEVICE...22226
      BLEED THE AIR OF AUTO-GREASING SYSTEM...22226
        METHOD FOR BLEEDING THE AIR OF AUTO-GREASING SYSTEM...22226
      CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES...22229
        METHOD FOR CHANGING THE LUBRICATION TIME AND LUBRICATION INTERVAL TIMES...22230
    Pm CLINIC...22232
      Pm CLINIC SERVICE...22232
        Pm CLINIC CHECK SHEET: WA380-8...22235
  40 TROUBLESHOOTING...22245
    CONTENTS...22246
    ABBREVIATION LIST...22259
    RELATED INFORMATION ON TROUBLESHOOTING...22265
      GENERAL TROUBLESHOOTING POINTS...22265
      TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM...22266
      SEQUENCE OF EVENTS IN TROUBLESHOOTING...22278
      CHECKS BEFORE TROUBLESHOOTING...22280
      INSPECTION PROCEDURE BEFORE TROUBLESHOOTING...22282
        WALK-AROUND CHECK...22282
      TESTING IN ACCORDANCE WITH TESTING PROCEDURE...22284
        CHECK FUEL LEVEL AND TYPE...22284
        FUEL - CHECK FOR FOREIGN MATERIAL...22284
        CHECK AdBule/DEF LEVEL AND TYPE...22285
        CHECK FUEL PREFILTER...22285
        CHECK MAIN FILTER...22287
        OIL PAN - CHECK ENGINE OIL LEVEL AND TYPE...22288
        CHECK COOLANT LEVEL (RESERVOIR TANK)...22289
        CHECK CLOGGING OF AIR CLEANER...22290
        OUTER ELEMENT - CLEAN...22290
        REPLACE ELEMENT...22292
        CHECK HYDRAULIC OIL LEVEL...22293
        CHECK HYDRAULIC OIL STRAINER...22294
        CHECK HYDRAULIC FILTER...22295
        CHECK OIL LEVEL IN TRANSMISSION CASE...22297
        CHECK OIL LEVEL IN FRONT AXLE CASE...22298
        CHECK OIL LEVEL IN REAR AXLE CASE...22299
        BLEED AIR FROM FUEL SYSTEM...22300
        BLEED AIR FROM HYDRAULIC SYSTEM...22300
        METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod...22300
      ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION...22306
      PROCEDURE FOR TESTING AND TROUBLESHOOTING...22318
      SYMPTOM AND TROUBLESHOOTING NUMBERS...22320
      INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...22325
      TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM...22327
      CONNECTORS LIST AND LAYOUT...22330
      CONNECTOR CONTACT IDENTIFICATION...22350
      T-BRANCH BOX AND T-BRANCH ADAPTER TABLE...22390
      FUSE LOCATION TABLE...22396
      PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)...22400
      PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR...22404
      PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT...22406
      PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])...22412
      FAILURE CODES TABLE...22414
    TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)...22438
      FAILURE CODE [1500L0]...22438
      FAILURE CODE [15SAL1]...22439
      FAILURE CODE [15SALH]...22441
      FAILURE CODE [15SBL1]...22443
      FAILURE CODE [15SBLH]...22445
      FAILURE CODE [15SEL1]...22447
      FAILURE CODE [15SELH]...22449
      FAILURE CODE [15SFL1]...22451
      FAILURE CODE [15SFLH]...22453
      FAILURE CODE [15SGL1]...22455
      FAILURE CODE [15SGLH]...22457
      FAILURE CODE [15SHL1]...22459
      FAILURE CODE [15SHLH]...22461
      FAILURE CODE [2F00MA]...22464
      FAILURE CODE [2F00MB]...22468
      FAILURE CODE [2G42ZG]...22471
      FAILURE CODE [2G43ZG]...22473
      FAILURE CODE [879AKA]...22475
      FAILURE CODE [879AKB]...22477
      FAILURE CODE [879BKA]...22479
      FAILURE CODE [879BKB]...22481
      FAILURE CODE [879CKA]...22483
      FAILURE CODE [879CKB]...22485
      FAILURE CODE [879DKZ]...22487
      FAILURE CODE [879EMC]...22489
      FAILURE CODE [879FMC]...22492
      FAILURE CODE [989A00]...22495
      FAILURE CODE [989L00]...22496
      FAILURE CODE [989M00]...22497
      FAILURE CODE [989N00]...22498
      FAILURE CODE [A1U0N3]...22499
      FAILURE CODE [A1U0N4]...22501
      FAILURE CODE [AA10NX]...22503
      FAILURE CODE [AB00KE]...22505
      FAILURE CODE [AB00KY]...22507
      FAILURE CODE [AQ10N3]...22509
      FAILURE CODE [AS00N3]...22511
      FAILURE CODE [AS00R2]...22513
      FAILURE CODE [AS00R3]...22514
      FAILURE CODE [AS00R4]...22515
      FAILURE CODE [AS00R5]...22516
      FAILURE CODE [AS00R6]...22517
      FAILURE CODE [AS00ZK]...22518
      FAILURE CODE [AS10KM]...22519
      FAILURE CODE [AS10NR]...22520
      FAILURE CODE [AS10NT]...22521
      FAILURE CODE [B@BAZG]...22522
      FAILURE CODE [B@BAZK]...22523
      FAILURE CODE [B@BCNS]...22525
      FAILURE CODE [B@BCZK]...22526
      FAILURE CODE [B@C7NS]...22528
      FAILURE CODE [B@CENS]...22530
      FAILURE CODE [B@HANS]...22531
      FAILURE CODE [CA115]...22532
      FAILURE CODE [CA122]...22533
      FAILURE CODE [CA123]...22535
      FAILURE CODE [CA131]...22537
      FAILURE CODE [CA132]...22539
      FAILURE CODE [CA144]...22542
      FAILURE CODE [CA145]...22544
      FAILURE CODE [CA153]...22546
      FAILURE CODE [CA154]...22549
      FAILURE CODE [CA187]...22551
      FAILURE CODE [CA221]...22553
      FAILURE CODE [CA222]...22555
      FAILURE CODE [CA227]...22557
      FAILURE CODE [CA234]...22558
      FAILURE CODE [CA238]...22559
      FAILURE CODE [CA239]...22561
      FAILURE CODE [CA249]...22563
      FAILURE CODE [CA256]...22565
      FAILURE CODE [CA271]...22567
      FAILURE CODE [CA272]...22569
      FAILURE CODE [CA322]...22571
      FAILURE CODE [CA323]...22573
      FAILURE CODE [CA324]...22575
      FAILURE CODE [CA325]...22577
      FAILURE CODE [CA331]...22579
      FAILURE CODE [CA332]...22581
      FAILURE CODE [CA343]...22583
      FAILURE CODE [CA351]...22584
      FAILURE CODE [CA352]...22585
      FAILURE CODE [CA356]...22588
      FAILURE CODE [CA357]...22590
      FAILURE CODE [CA386]...22593
      FAILURE CODE [CA428]...22594
      FAILURE CODE [CA429]...22596
      FAILURE CODE [CA431]...22598
      FAILURE CODE [CA432]...22601
      FAILURE CODE [CA435]...22605
      FAILURE CODE [CA441]...22607
      FAILURE CODE [CA442]...22609
      FAILURE CODE [CA449]...22610
      FAILURE CODE [CA451]...22611
      FAILURE CODE [CA452]...22613
      FAILURE CODE [CA488]...22615
      FAILURE CODE [CA515]...22616
      FAILURE CODE [CA516]...22618
      FAILURE CODE [CA553]...22620
      FAILURE CODE [CA555]...22621
      FAILURE CODE [CA556]...22622
      FAILURE CODE [CA559]...22623
      FAILURE CODE [CA595]...22626
      FAILURE CODE [CA687]...22627
      FAILURE CODE [CA689]...22629
      FAILURE CODE [CA691]...22632
      FAILURE CODE [CA692]...22634
      FAILURE CODE [CA697]...22636
      FAILURE CODE [CA698]...22637
      FAILURE CODE [CA731]...22638
      FAILURE CODE [CA778]...22640
      FAILURE CODE [CA1117]...22645
      FAILURE CODE [CA1664]...22646
      FAILURE CODE [CA1669]...22649
      FAILURE CODE [CA1673]...22650
      FAILURE CODE [CA1677]...22651
      FAILURE CODE [CA1678]...22652
      FAILURE CODE [CA1682]...22653
      FAILURE CODE [CA1683]...22655
      FAILURE CODE [CA1684]...22657
      FAILURE CODE [CA1686]...22659
      FAILURE CODE [CA1691]...22660
      FAILURE CODE [CA1694]...22663
      FAILURE CODE [CA1695]...22666
      FAILURE CODE [CA1696]...22667
      FAILURE CODE [CA1712]...22669
      FAILURE CODE [CA1713]...22672
      FAILURE CODE [CA1714]...22674
      FAILURE CODE [CA1715]...22675
      FAILURE CODE [CA1776]...22676
      FAILURE CODE [CA1777]...22679
      FAILURE CODE [CA1843]...22682
      FAILURE CODE [CA1844]...22684
      FAILURE CODE [CA1879]...22687
      FAILURE CODE [CA1881]...22690
      FAILURE CODE [CA1883]...22692
      FAILURE CODE [CA1885]...22696
      FAILURE CODE [CA1887]...22698
      FAILURE CODE [CA1921]...22700
      FAILURE CODE [CA1922]...22703
      FAILURE CODE [CA1942]...22708
      FAILURE CODE [CA1993]...22709
      FAILURE CODE [CA2185]...22712
      FAILURE CODE [CA2186]...22714
      FAILURE CODE [CA2249]...22716
      FAILURE CODE [CA2271]...22717
      FAILURE CODE [CA2272]...22720
      FAILURE CODE [CA2288]...22723
      FAILURE CODE [CA2311]...22724
      FAILURE CODE [CA2349]...22725
      FAILURE CODE [CA2353]...22728
      FAILURE CODE [CA2357]...22730
      FAILURE CODE [CA2381]...22731
      FAILURE CODE [CA2382]...22734
      FAILURE CODE [CA2383]...22737
      FAILURE CODE [CA2386]...22740
      FAILURE CODE [CA2387]...22742
      FAILURE CODE [CA2555]...22743
      FAILURE CODE [CA2556]...22746
      FAILURE CODE [CA2637]...22748
      FAILURE CODE [CA2639]...22750
      FAILURE CODE [CA2771]...22753
      FAILURE CODE [CA2777]...22759
      FAILURE CODE [CA2976]...22762
      FAILURE CODE [CA3133]...22764
      FAILURE CODE [CA3134]...22767
      FAILURE CODE [CA3135]...22769
      FAILURE CODE [CA3142]...22773
      FAILURE CODE [CA3143]...22774
      FAILURE CODE [CA3144]...22775
      FAILURE CODE [CA3146]...22778
      FAILURE CODE [CA3147]...22779
      FAILURE CODE [CA3148]...22780
      FAILURE CODE [CA3151]...22782
      FAILURE CODE [CA3165]...22788
      FAILURE CODE [CA3229]...22790
      FAILURE CODE [CA3231]...22792
      FAILURE CODE [CA3232]...22794
      FAILURE CODE [CA3235]...22798
      FAILURE CODE [CA3239]...22800
      FAILURE CODE [CA3241]...22803
      FAILURE CODE [CA3242]...22806
      FAILURE CODE [CA3251]...22809
      FAILURE CODE [CA3253]...22811
      FAILURE CODE [CA3254]...22814
      FAILURE CODE [CA3255]...22817
      FAILURE CODE [CA3256]...22821
      FAILURE CODE [CA3311]...22823
      FAILURE CODE [CA3312]...22825
      FAILURE CODE [CA3313]...22828
      FAILURE CODE [CA3314]...22829
      FAILURE CODE [CA3315]...22830
      FAILURE CODE [CA3316]...22833
      FAILURE CODE [CA3317]...22834
      FAILURE CODE [CA3318]...22835
      FAILURE CODE [CA3319]...22838
      FAILURE CODE [CA3321]...22839
      FAILURE CODE [CA3322]...22841
      FAILURE CODE [CA3419]...22844
      FAILURE CODE [CA3421]...22846
      FAILURE CODE [CA3497]...22848
      FAILURE CODE [CA3498]...22849
      FAILURE CODE [CA3543]...22850
      FAILURE CODE [CA3545]...22857
      FAILURE CODE [CA3547]...22859
      FAILURE CODE [CA3558]...22860
      FAILURE CODE [CA3559]...22862
      FAILURE CODE [CA3562]...22864
      FAILURE CODE [CA3563]...22866
      FAILURE CODE [CA3567]...22869
      FAILURE CODE [CA3568]...22873
      FAILURE CODE [CA3571]...22877
      FAILURE CODE [CA3572]...22879
      FAILURE CODE [CA3574]...22881
      FAILURE CODE [CA3575]...22883
      FAILURE CODE [CA3577]...22885
      FAILURE CODE [CA3578]...22887
      FAILURE CODE [CA3582]...22889
      FAILURE CODE [CA3583]...22895
      FAILURE CODE [CA3596]...22897
      FAILURE CODE [CA3649]...22899
      FAILURE CODE [CA3681]...22901
      FAILURE CODE [CA3682]...22906
      FAILURE CODE [CA3713]...22912
      FAILURE CODE [CA3717]...22915
      FAILURE CODE [CA3718]...22916
      FAILURE CODE [CA3725]...22917
      FAILURE CODE [CA3741]...22920
      FAILURE CODE [CA3748]...22921
      FAILURE CODE [CA3751]...22924
      FAILURE CODE [CA3755]...22926
      FAILURE CODE [CA3866]...22928
      FAILURE CODE [CA3867]...22931
      FAILURE CODE [CA3868]...22934
      FAILURE CODE [CA3899]...22938
      FAILURE CODE [CA3911]...22940
      FAILURE CODE [CA3912]...22944
      FAILURE CODE [CA3932]...22946
      FAILURE CODE [CA3933]...22948
      FAILURE CODE [CA3934]...22950
      FAILURE CODE [CA3935]...22953
      FAILURE CODE [CA3936]...22955
      FAILURE CODE [CA4151]...22957
      FAILURE CODE [CA4152]...22961
      FAILURE CODE [CA4155]...22965
      FAILURE CODE [CA4156]...22968
      FAILURE CODE [CA4157]...22971
      FAILURE CODE [CA4158]...22973
      FAILURE CODE [CA4159]...22974
      FAILURE CODE [CA4161]...22975
      FAILURE CODE [CA4162]...22978
      FAILURE CODE [CA4163]...22981
      FAILURE CODE [CA4164]...22983
      FAILURE CODE [CA4165]...22985
      FAILURE CODE [CA4166]...22987
      FAILURE CODE [CA4168]...22989
      FAILURE CODE [CA4169]...22992
      FAILURE CODE [CA4171]...22994
      FAILURE CODE [CA4249]...22997
      FAILURE CODE [CA4251]...22999
      FAILURE CODE [CA4259]...23001
      FAILURE CODE [CA4261]...23004
      FAILURE CODE [CA4277]...23007
      FAILURE CODE [CA4281]...23010
      FAILURE CODE [CA4459]...23013
      FAILURE CODE [CA4461]...23016
      FAILURE CODE [CA4658]...23019
      FAILURE CODE [CA4731]...23023
      FAILURE CODE [CA4732]...23024
      FAILURE CODE [CA4739]...23025
      FAILURE CODE [CA4768]...23026
      FAILURE CODE [CA4769]...23028
      FAILURE CODE [CA4842]...23031
      FAILURE CODE [CA4952]...23034
      FAILURE CODE [CA5115]...23036
      FAILURE CODE [CA5179]...23039
      FAILURE CODE [CA5181]...23041
      FAILURE CODE [CA5383]...23043
      FAILURE CODE [D150KA]...23045
      FAILURE CODE [D150KB]...23047
      FAILURE CODE [D150KY]...23049
      FAILURE CODE [D160KA]...23051
      FAILURE CODE [D160KB]...23053
      FAILURE CODE [D160KY]...23055
      FAILURE CODE [D191KA]...23057
      FAILURE CODE [D191KB]...23060
      FAILURE CODE [D191KY]...23063
      FAILURE CODE [D192KA]...23065
      FAILURE CODE [D192KB]...23067
      FAILURE CODE [D192KY]...23069
      FAILURE CODE [D19JKZ]...23070
      FAILURE CODE [D1E6KA]...23072
      FAILURE CODE [D1E6KB]...23074
      FAILURE CODE [D1E6KY]...23076
      FAILURE CODE [D5ZHKA]...23078
      FAILURE CODE [D5ZHKB]...23080
      FAILURE CODE [D5ZHKZ]...23082
      FAILURE CODE [D5ZHL6]...23085
      FAILURE CODE [D5ZMLD]...23087
      FAILURE CODE [D811MC]...23089
      FAILURE CODE [D862KA]...23090
      FAILURE CODE [D8ALKA]...23091
      FAILURE CODE [D8ALKB]...23093
      FAILURE CODE [D8AQK4]...23095
      FAILURE CODE [D8AQKR]...23096
      FAILURE CODE [DAF0KT]...23098
      FAILURE CODE [DAF0MB]...23099
      FAILURE CODE [DAF0MC]...23100
      FAILURE CODE [DAF3KK]...23101
      FAILURE CODE [DAF8KB]...23103
      FAILURE CODE [DAFDKB]...23105
      FAILURE CODE [DAFGMC]...23107
      FAILURE CODE [DAFLKA]...23108
      FAILURE CODE [DAFLKB]...23110
      FAILURE CODE [DAFQKR]...23112
      FAILURE CODE [DAQ0KK]...23113
      FAILURE CODE [DAQ0KT]...23116
      FAILURE CODE [DAQ0MC]...23117
      FAILURE CODE [DAQ1KA]...23118
      FAILURE CODE [DAQ2KK]...23120
      FAILURE CODE [DAQ4KB]...23123
      FAILURE CODE [DAQ9KQ]...23125
      FAILURE CODE [DAQLKA]...23126
      FAILURE CODE [DAQLKB]...23128
      FAILURE CODE [DAQQKR]...23130
      FAILURE CODE [DAQRKR]...23131
      FAILURE CODE [DAQRMA]...23132
      FAILURE CODE [DAZ9KQ]...23133
      FAILURE CODE [DAZQKR]...23134
      FAILURE CODE [DB2QKR]...23135
      FAILURE CODE [DB2RKR]...23140
      FAILURE CODE [DB90KK]...23146
      FAILURE CODE [DB90KT]...23149
      FAILURE CODE [DB90MC]...23150
      FAILURE CODE [DB91KA]...23151
      FAILURE CODE [DB92KK]...23153
      FAILURE CODE [DB95KX]...23156
      FAILURE CODE [DB96KX]...23159
      FAILURE CODE [DB99KQ]...23161
      FAILURE CODE [DB9LKA]...23162
      FAILURE CODE [DB9LKB]...23164
      FAILURE CODE [DB9QKR]...23166
      FAILURE CODE [DB9RKR]...23167
      FAILURE CODE [DB9RMA]...23168
      FAILURE CODE [DBE5KX]...23169
      FAILURE CODE [DBE6KX]...23171
      FAILURE CODE [DD1ALD]...23173
      FAILURE CODE [DDAAL6]...23175
      FAILURE CODE [DDB6L4]...23177
      FAILURE CODE [DDD1LD]...23180
      FAILURE CODE [DDK3KA]...23182
      FAILURE CODE [DDK3KB]...23185
      FAILURE CODE [DDK6KA]...23188
      FAILURE CODE [DDK6KB]...23191
      FAILURE CODE [DDKLKA]...23194
      FAILURE CODE [DDKLKB]...23197
      FAILURE CODE [DDNRKY]...23199
      FAILURE CODE [DDNTKY]...23201
      FAILURE CODE [DDT0L4]...23203
      FAILURE CODE [DDT4LD]...23205
      FAILURE CODE [DDT9LD]...23207
      FAILURE CODE [DDTALD]...23209
      FAILURE CODE [DDW9LD]...23211
      FAILURE CODE [DDWLLD]...23213
      FAILURE CODE [DF10KA]...23215
      FAILURE CODE [DF10KB]...23218
      FAILURE CODE [DGF1KA]...23221
      FAILURE CODE [DGF1KB]...23223
      FAILURE CODE [DGH2KX]...23225
      FAILURE CODE [DGR2KB]...23227
      FAILURE CODE [DGR2KZ]...23229
      FAILURE CODE [DGT1KA]...23231
      FAILURE CODE [DGT1KB]...23233
      FAILURE CODE [DH21KA]...23235
      FAILURE CODE [DH21KB]...23238
      FAILURE CODE [DHA4KA]...23240
      FAILURE CODE [DHAAMA]...23242
      FAILURE CODE [DHACMA]...23244
      FAILURE CODE [DHPCKX]...23246
      FAILURE CODE [DHPDKX]...23249
      FAILURE CODE [DHT1KX]...23252
      FAILURE CODE [DHT5KX]...23255
      FAILURE CODE [DHT7KX]...23258
      FAILURE CODE [DHT8KA]...23261
      FAILURE CODE [DHT8KB]...23264
      FAILURE CODE [DHT8ZG]...23266
      FAILURE CODE [DHUDKA]...23267
      FAILURE CODE [DHUDKB]...23270
      FAILURE CODE [DJF1KA]...23272
      FAILURE CODE [DK55KA]...23274
      FAILURE CODE [DK55KY]...23277
      FAILURE CODE [DK55L5]...23279
      FAILURE CODE [DK59KA]...23280
      FAILURE CODE [DK59KY]...23284
      FAILURE CODE [DK59L8]...23288
      FAILURE CODE [DK5AKA]...23293
      FAILURE CODE [DK5AKY]...23297
      FAILURE CODE [DK5BKA]...23301
      FAILURE CODE [DK5BKY]...23305
      FAILURE CODE [DK5BL8]...23309
      FAILURE CODE [DK5CKA]...23314
      FAILURE CODE [DK5CKY]...23318
      FAILURE CODE [DK5DKA]...23322
      FAILURE CODE [DK5DKY]...23325
      FAILURE CODE [DK5DL8]...23328
      FAILURE CODE [DK5EKA]...23332
      FAILURE CODE [DK5EKY]...23335
      FAILURE CODE [DK5KKA]...23338
      FAILURE CODE [DK5KKY]...23341
      FAILURE CODE [DK5KL8]...23344
      FAILURE CODE [DK5LKA]...23348
      FAILURE CODE [DK5LKY]...23351
      FAILURE CODE [DKA0KA]...23354
      FAILURE CODE [DKA0KY]...23357
      FAILURE CODE [DKA0L0]...23360
      FAILURE CODE [DKA1KA]...23363
      FAILURE CODE [DKA1KY]...23366
      FAILURE CODE [DLF1KA]...23369
      FAILURE CODE [DLF1LC]...23371
      FAILURE CODE [DLM3KA]...23373
      FAILURE CODE [DLM3LC]...23375
      FAILURE CODE [DLT3KA]...23377
      FAILURE CODE [DLT3LC]...23379
      FAILURE CODE [DPQ1KR]...23381
      FAILURE CODE [DPQ2KR]...23384
      FAILURE CODE [DPQ3KR]...23387
      FAILURE CODE [DSJ0KR]...23390
      FAILURE CODE [DT20KB]...23393
      FAILURE CODE [DT22KB]...23395
      FAILURE CODE [DT23KB]...23397
      FAILURE CODE [DV00KB]...23399
      FAILURE CODE [DW4PKA]...23401
      FAILURE CODE [DW4PKB]...23403
      FAILURE CODE [DW4PKY]...23405
      FAILURE CODE [DW4QKA]...23407
      FAILURE CODE [DW4QKB]...23409
      FAILURE CODE [DW4QKY]...23411
      FAILURE CODE [DW4RKA]...23413
      FAILURE CODE [DW4RKB]...23415
      FAILURE CODE [DW4RKY]...23417
      FAILURE CODE [DW4SKA]...23419
      FAILURE CODE [DW4SKB]...23421
      FAILURE CODE [DW4SKY]...23423
      FAILURE CODE [DW7BKA]...23425
      FAILURE CODE [DW7BKB]...23427
      FAILURE CODE [DW7BKY]...23429
      FAILURE CODE [DWM1KA]...23431
      FAILURE CODE [DWM1KB]...23433
      FAILURE CODE [DWM1KY]...23435
      FAILURE CODE [DWN6KA]...23437
      FAILURE CODE [DWN6KB]...23439
      FAILURE CODE [DWN6KY]...23441
      FAILURE CODE [DWN8KA]...23443
      FAILURE CODE [DWN8KB]...23445
      FAILURE CODE [DWN8KY]...23447
      FAILURE CODE [DX16KA]...23449
      FAILURE CODE [DX16KB]...23451
      FAILURE CODE [DX16KY]...23453
      FAILURE CODE [DXA1KA]...23455
      FAILURE CODE [DXA1KB]...23457
      FAILURE CODE [DXA1KY]...23459
      FAILURE CODE [DXANKA]...23461
      FAILURE CODE [DXANKB]...23463
      FAILURE CODE [DXANKY]...23465
      FAILURE CODE [DXH1KA]...23467
      FAILURE CODE [DXH1KB]...23469
      FAILURE CODE [DXH1KY]...23471
      FAILURE CODE [DXH4KA]...23473
      FAILURE CODE [DXH4KB]...23475
      FAILURE CODE [DXH4KY]...23477
      FAILURE CODE [DXH5KA]...23479
      FAILURE CODE [DXH5KB]...23481
      FAILURE CODE [DXH5KY]...23483
      FAILURE CODE [DXH6KA]...23485
      FAILURE CODE [DXH6KB]...23487
      FAILURE CODE [DXH6KY]...23489
      FAILURE CODE [DXH7KA]...23491
      FAILURE CODE [DXH7KB]...23493
      FAILURE CODE [DXH7KY]...23495
      FAILURE CODE [DXH8KA]...23497
      FAILURE CODE [DXH8KB]...23499
      FAILURE CODE [DXH8KY]...23501
      FAILURE CODE [DXHHKA]...23503
      FAILURE CODE [DXHHKB]...23505
      FAILURE CODE [DXHHKY]...23507
      FAILURE CODE [DXHJKA]...23509
      FAILURE CODE [DXHJKB]...23511
      FAILURE CODE [DXHJKY]...23513
      FAILURE CODE [DXHKKA]...23515
      FAILURE CODE [DXHKKB]...23517
      FAILURE CODE [DXHKKY]...23519
      FAILURE CODE [DXJEKA]...23521
      FAILURE CODE [DXJEKB]...23523
      FAILURE CODE [DXJEKY]...23525
      FAILURE CODE [DXJFKA]...23527
      FAILURE CODE [DXJFKB]...23529
      FAILURE CODE [DXJFKY]...23531
      FAILURE CODE [DY30MA]...23533
      FAILURE CODE [DY30MC]...23537
      FAILURE CODE [DY30ME]...23542
      FAILURE CODE [LA00L3]...23544
    TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...23545
      E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...23545
      E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK...23552
      E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK...23555
      E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP...23558
      E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING...23560
      E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING...23563
      E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)...23566
      E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY...23569
      E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL...23572
      E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL...23575
      E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL...23579
      E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY...23581
      E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION...23584
      E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL...23587
      E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY...23590
      E-16 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS...23591
      E-17 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY...23594
      E-18 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED...23597
      E-19 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL...23601
      E-20 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP...23603
      E-21 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP...23605
      E-22 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION...23607
      E-23 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...23611
      E-24 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...23612
      E-25 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL...23613
      E-26 TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP...23615
      E-27 INDICATION OF HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT...23616
      E-28 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL...23618
      E-29 ALARM BUZZER DOES NOT SOUND...23619
      E-30 ALARM BUZZER DOES NOT STOP SOUNDING...23621
      E-31 KICKDOWN DOES NOT WORK WHEN KICKDOWN SWITCH IS TURNED ON...23622
      E-32 HOLD SWITCH DOES NOT WORK WHEN IT IS PRESSED...23624
      E-33 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED...23626
      E-34 TRANSMISSION CUT-OFF MODE IS NOT SELECTED OR NOT RELEASED...23630
      E-35 TRANSMISSION CUT-OFF SETTING CANNOT BE RELEASED...23632
      E-36 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED...23634
      E-37 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE NORMALLY WHEN ENGINE POWER MODE SELECTOR SWITCH IS OPERATED...23636
      E-38 FLOW OF LOADER PUMP DOES NOT INCREASE FROM THE MINIMUM RATE...23638
      E-39 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED...23639
      E-40 HORN DOES NOT SOUND...23641
      E-41 HORN DOES NOT STOP SOUNDING...23644
      E-42 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS...23646
      E-43 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT...23648
      E-44 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT...23652
      E-45 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT...23656
      E-46 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT...23658
      E-47 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT...23660
      E-48 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)...23665
      E-49 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT...23670
      E-50 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)...23674
      E-51 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT...23679
      E-52 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT...23682
      E-53 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT...23685
      E-54 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED...23689
      E-55 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT...23693
      E-56 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND...23696
      E-57 FRONT WIPER DOES NOT OPERATE...23698
      E-58 REAR WIPER DOES NOT OPERATE...23702
      E-59 WINDOW WASHER DOES NOT OPERATE...23705
      E-60 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...23708
      E-61 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP...23709
      E-62 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP...23711
      E-63 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP...23712
    TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...23714
      INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...23714
      FAILURE MODE AND CAUSE TABLE...23715
      H-1 MACHINE DOES NOT START...23728
      H-2 LOCKUP IS NOT RELEASED...23732
      H-3 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE...23733
      H-4 TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADABILITY IS LOW, OR GEAR SPEED DOES NOT SHIFT...23734
      H-5 LARGE SHOCK IS MADE WHEN MACHINE MOVES OFF OR GEAR IS SHIFTED...23737
      H-6 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED...23740
      H-7 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH...23743
      H-8 MACHINE DOES NOT TURN (FOR STEERING WHEEL SPEC)...23746
      H-9 TURNING RESPONSE IS POOR (FOR STEERING WHEEL SPEC)...23749
      H-10 STEERING WHEEL IS HEAVY TO OPERATE...23752
      H-11 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (FOR STEERING WHEEL SPEC)...23753
      H-12 TURNING RADIUS DIFFERS BETWEEN RIGHT AND LEFT TURNS...23755
      H-13 WHEEL BRAKES DO NOT WORK OR ARE WEAK...23756
      H-14 WHEEL BRAKES ARE NOT RELEASED OR DRAG...23758
      H-15 PARKING BRAKE DOES NOT WORK OR IT IS WEAK...23759
      H-16 PARKING BRAKE IS NOT RELEASED OR DRAGS...23760
      H-17 BOOM DOES NOT RISE...23761
      H-18 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE...23764
      H-19 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT...23767
      H-20 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND...23768
      H-21 HYDRAULIC DRIFT OF BOOM IS LARGE...23770
      H-22 BOOM MOVES UP AND DOWN DURING OPERATION...23771
      H-23 BUCKET DOES NOT TILT BACK...23772
      H-24 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE...23775
      H-25 BUCKET DECELERATES DURING TILT-BACK OPERATION...23778
      H-26 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND...23779
      H-27 HYDRAULIC DRIFT OF BUCKET IS LARGE...23781
      H-28 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD)...23782
      H-29 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE (2-LEVER TYPE OR 3-LEVER TYPE)...23783
      H-30 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE (MULTI-FUNCTION MONO-LEVER TYPE)...23784
      H-31 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS...23785
      H-32 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS...23786
      H-33 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES...23788
      H-34 E.C.S.S. (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES...23789
      H-35 BUCKET DOES NOT STOP AT THE POSITION WHICH IS SET WITH REMOTE BUCKET POSITIONER...23790
      H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)...23791
      H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN...23793
    TROUBLESHOOTING OF ENGINE (S-MODE)...23794
      INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...23794
      S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION...23795
      S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT...23796
      S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)...23797
      S-4 ENGINE STARTABILITY IS POOR...23799
      S-5 ENGINE DOES NOT PICK UP SMOOTHLY...23801
      S-6 ENGINE STOPS DURING OPERATION...23803
      S-7 ENGINE RUNS ROUGH OR IS UNSTABLE...23805
      S-8 ENGINE LACKS POWER...23806
      S-9 KDPF GETS CLOGGED IN A SHORT TIME...23808
      S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE...23810
      S-11 OIL BECOMES CONTAMINATED QUICKLY...23811
      S-12 FUEL CONSUMPTION IS EXCESSIVE...23812
      S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)...23813
      S-14 OIL PRESSURE DROPS...23814
      S-15 FUEL MIXES INTO ENGINE OIL...23816
      S-16 WATER MIXES INTO ENGINE OIL (MILKY)...23817
      S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...23818
      S-18 UNUSUAL NOISE IS HEARD...23819
      S-19 VIBRATION IS EXCESSIVE...23820
      S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT...23821
      S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY...23822
      S-22 ACTIVE REGENERATION TAKES TIME...23824
      S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION...23825
      S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE...23826
      S-25 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)...23828
    TROUBLESHOOTING FOR AUTO-GREASING SYSTEM...23829
      OUTLINE OF FAILURE DISPLAY...23829
      TROUBLESHOOTING FOR FCS...23830
      TROUBLESHOOTING FOR AUTO-GREASING PUMP...23831
      REPLACEMENT OF PUMP ELEMENT...23834
      TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM...23835
      REPLACEMENT OF AUTO-GREASING CONTROLLER...23837
      PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING...23838
  50 DISASSEMBLY AND ASSEMBLY...23839
    CONTENTS...23840
    ABBREVIATION LIST...23845
    RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY...23851
      HOW TO READ THIS MANUAL...23851
      COATING MATERIALS LIST...23853
      SPECIAL TOOLS LIST...23858
      SKETCHES OF SPECIAL TOOLS...23877
    ENGINE AND COOLING SYSTEM...23885
      REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY...23885
        METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY...23885
        METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY...23888
      REMOVE AND INSTALL INJECTOR ASSEMBLY...23891
        METHOD FOR REMOVING INJECTOR ASSEMBLY...23891
        METHOD FOR INSTALLING INJECTOR ASSEMBLY...23897
      REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY...23906
        METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY...23907
        METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY...23918
      REMOVE AND INSTALL EGR VALVE ASSEMBLY...23934
        METHOD FOR REMOVING EGR VALVE ASSEMBLY...23934
        METHOD FOR INSTALLING EGR VALVE ASSEMBLY...23935
      REMOVE AND INSTALL EGR COOLER ASSEMBLY...23937
        METHOD FOR REMOVING EGR COOLER ASSEMBLY...23937
        METHOD FOR INSTALLING EGR COOLER ASSEMBLY...23939
      REMOVE AND INSTALL STARTING MOTOR ASSEMBLY...23943
        METHOD FOR REMOVING STARTING MOTOR ASSEMBLY...23943
        METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY...23944
      REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT...23946
        METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT...23946
        METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT...23947
      REMOVE AND INSTALL ALTERNATOR BELT...23949
        METHOD FOR REMOVING ALTERNATOR BELT...23949
        METHOD FOR INSTALLING ALTERNATOR BELT...23950
      REMOVE AND INSTALL AUTOMATIC TENSIONER...23952
        METHOD FOR REMOVING AUTOMATIC TENSIONER...23952
        METHOD FOR INSTALLING AUTOMATIC TENSIONER...23952
      REMOVE AND INSTALL RADIATOR CORE...23953
        METHOD FOR REMOVING RADIATOR CORE...23953
        METHOD FOR INSTALLING RADIATOR CORE...23960
      REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY...23967
        METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY...23967
        METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY...23970
      REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY...23973
        METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY...23973
        METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY...23975
      REMOVE AND INSTALL AFTERCOOLER ASSEMBLY...23977
        METHOD FOR REMOVING AFTERCOOLER ASSEMBLY...23977
        METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY...23981
      REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY...23986
        METHOD FOR REMOVING POWER TRAIN OIL COOLER ASSEMBLY...23986
        METHOD FOR INSTALLING POWER TRAIN OIL COOLER ASSEMBLY...23989
      REMOVE AND INSTALL ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...23993
        METHOD FOR REMOVING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...23994
        METHOD FOR INSTALLING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...24008
      DISCONNECT AND CONNECT ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...24023
        METHOD FOR DISCONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...24023
        METHOD FOR CONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...24024
      REMOVE AND INSTALL ENGINE FRONT OIL SEAL...24025
        METHOD FOR REMOVING ENGINE FRONT OIL SEAL...24025
        METHOD FOR INSTALLING ENGINE FRONT OIL SEAL...24026
      REMOVE AND INSTALL ENGINE REAR OIL SEAL...24028
        METHOD FOR REMOVING ENGINE REAR OIL SEAL...24028
        METHOD FOR INSTALLING ENGINE REAR OIL SEAL...24029
      REMOVE AND INSTALL ENGINE HOOD ASSEMBLY...24033
        METHOD FOR REMOVING ENGINE HOOD ASSEMBLY...24033
        METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY...24037
      REMOVE AND INSTALL FUEL TANK ASSEMBLY...24041
        METHOD FOR REMOVING FUEL TANK ASSEMBLY...24041
        METHOD FOR INSTALLING FUEL TANK ASSEMBLY...24043
      REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY...24046
        METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY...24046
        METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY...24051
      REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...24055
        METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...24055
        METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...24055
      REMOVE AND INSTALL AdBlue/DEF TANK SENSOR...24057
        METHOD FOR REMOVING AdBlue/DEF TANK SENSOR...24057
        METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR...24057
      REMOVE AND INSTALL AdBlue/DEF TANK STRAINER...24059
        METHOD FOR REMOVING AdBlue/DEF TANK STRAINER...24059
        METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER...24059
      REMOVE AND INSTALL KDPF ASSEMBLY...24060
        METHOD FOR REMOVING KDPF ASSEMBLY...24061
        METHOD FOR INSTALLING KDPF ASSEMBLY...24070
      DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY...24083
        METHOD FOR DISASSEMBLING KDPF ASSEMBLY...24083
        METHOD FOR ASSEMBLING KDPF ASSEMBLY...24087
      REMOVE AND INSTALL SCR ASSEMBLY...24092
        METHOD FOR REMOVING SCR ASSEMBLY...24093
        METHOD FOR INSTALLING SCR ASSEMBLY...24101
      REMOVE AND INSTALL KDPF, SCR ASSEMBLY...24113
        METHOD FOR REMOVING KDPF, SCR ASSEMBLY...24113
        METHOD FOR INSTALLING KDPF, SCR ASSEMBLY...24121
      REMOVE AND INSTALL KCCV ASSEMBLY...24131
        METHOD FOR REMOVING KCCV ASSEMBLY...24131
        METHOD FOR INSTALLING KCCV ASSEMBLY...24132
      REMOVE AND INSTALL VGT ASSEMBLY...24134
        METHOD FOR REMOVING KVGT ASSEMBLY...24134
        METHOD FOR INSTALLING KVGT ASSEMBLY...24137
      REMOVE AND INSTALL AdBlue/DEF MIXING TUBE...24141
        METHOD FOR REMOVING AdBlue/DEF MIXING TUBE...24142
        METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE...24149
      REMOVE AND INSTALL AdBlue/DEF INJECTOR...24157
        METHOD FOR REMOVING AdBlue/DEF INJECTOR...24157
        METHOD FOR INSTALLING AdBlue/DEF INJECTOR...24160
      REMOVE AND INSTALL AdBlue/DEF PUMP...24163
        METHOD FOR REMOVING AdBlue/DEF PUMP...24163
        METHOD FOR INSTALLING AdBlue/DEF PUMP...24166
      REMOVE AND INSTALL AdBlue/DEF HOSE...24169
        METHOD FOR REMOVING AdBlue/DEF HOSE...24170
        METHOD FOR INSTALLING AdBlue/DEF HOSE...24175
      REMOVE AND INSTALL AIR CLEANER ASSEMBLY...24183
        METHOD FOR REMOVING AIR CLEANER ASSEMBLY...24183
        METHOD FOR INSTALLING AIR CLEANER ASSEMBLY...24185
      REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY...24187
        METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY...24187
        METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY...24189
      REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...24192
        METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY...24192
        METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY...24193
    POWER TRAIN...24195
      DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY...24195
        METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY...24196
        METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY...24199
      DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY...24205
        METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY...24206
        METHOD FOR ASSEMBLING TRANSMISSION ASSEMBLY...24214
      DISASSEMBLE AND ASSEMBLE TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY...24226
        METHOD FOR DISASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY...24227
        METHOD FOR ASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY...24236
      DISASSEMBLE AND ASSEMBLE PARKING BRAKE ASSEMBLY...24248
        METHOD FOR DISASSEMBLING PARKING BRAKE ASSEMBLY...24249
        METHOD FOR ASSEMBLING PARKING BRAKE ASSEMBLY...24251
      REMOVE AND INSTALL FRONT AXLE ASSEMBLY...24259
        METHOD FOR REMOVING FRONT AXLE ASSEMBLY...24259
        METHOD FOR INSTALLING FRONT AXLE ASSEMBLY...24260
      REMOVE AND INSTALL REAR AXLE ASSEMBLY...24263
        METHOD FOR REMOVING REAR AXLE ASSEMBLY...24263
        METHOD FOR INSTALLING REAR AXLE ASSEMBLY...24266
      DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY...24271
        METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY...24272
        METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY...24277
      DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY...24285
        METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY...24286
        METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY...24296
    STEERING SYSTEM...24314
      REMOVE AND INSTALL STEERING VALVE ASSEMBLY...24314
        METHOD FOR REMOVING STEERING VALVE ASSEMBLY...24314
        METHOD FOR INSTALLING STEERING VALVE ASSEMBLY...24316
    BRAKE SYSTEM...24319
      REMOVE AND INSTALL PARKING BRAKE DISC AND PLATE...24319
        METHOD FOR REMOVING PARKING BRAKE DISC AND PLATE...24319
        METHOD FOR INSTALLING PARKING BRAKE DISC AND PLATE...24322
    UNDERCARRIAGE AND FRAME...24325
      REMOVE AND INSTALL CENTER HINGE PIN...24325
        METHOD FOR REMOVING CENTER HINGE PIN...24325
        METHOD FOR INSTALLING CENTER HINGE PIN...24330
      REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...24337
        METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY...24337
        METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY...24342
      REMOVE AND INSTALL FULL-LENGTH FENDER ASSEMBLY...24347
        METHOD FOR REMOVING FULL-LENGTH FENDER ASSEMBLY...24347
        METHOD FOR INSTALLING FULL-LENGTH FENDER ASSEMBLY...24348
    HYDRAULIC SYSTEM...24349
      REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...24349
        METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY...24349
        METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY...24352
      REMOVE AND INSTALL WORK EQUIPMENT PUMP AND POWER TRAIN PUMP ASSEMBLY...24356
        METHOD FOR REMOVING WORK EQUIPMENT PUMP AND POWER TRAIN PUMP ASSEMBLY...24356
        METHOD FOR INSTALLING WORK EQUIPMENT PUMP AND POWER TRAIN PUMP ASSEMBLY...24358
      REMOVE AND INSTALL STEERING PUMP AND COOLING FAN PUMP ASSEMBLY...24360
        METHOD FOR REMOVING STEERING PUMP AND COOLING FAN PUMP ASSEMBLY...24360
        METHOD FOR INSTALLING STEERING PUMP AND COOLING FAN PUMP ASSEMBLY...24362
      REMOVE AND INSTALL CONTROL VALVE ASSEMBLY...24364
        METHOD FOR REMOVING CONTROL VALVE ASSEMBLY...24364
        METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY...24368
    WORK EQUIPMENT...24372
      REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY...24372
        METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY...24372
        METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY...24376
      DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLY...24382
        METHOD FOR DISASSEMBLING HYDRAULIC CYLINDER ASSEMBLY...24383
        METHOD FOR ASSEMBLING HYDRAULIC CYLINDER ASSEMBLY...24386
    CAB AND ITS ATTACHMENTS...24392
      REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY...24392
        METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY...24392
        METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY...24396
      REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS)...24402
        METHOD FOR REMOVING OPERATOR'S CAB GLASS (ADHERED GLASS)...24402
        METHOD FOR INSTALLING OPERATOR'S CAB GLASS (ADHERED GLASS)...24403
      REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY...24412
        METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY...24412
        METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY...24418
      REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY...24424
        METHOD FOR REMOVING OPERATOR'S SEAT ASSEMBLY...24424
        METHOD FOR INSTALLING OPERATOR'S SEAT ASSEMBLY...24426
      REMOVE AND INSTALL SEAT BELT...24428
        METHOD FOR REMOVING SEAT BELT...24428
        METHOD FOR INSTALLING SEAT BELT...24428
    ELECTRICAL SYSTEM...24430
      REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...24430
        METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY...24430
        METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY...24432
      REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY...24435
        METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY...24435
        METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY...24436
      REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY...24439
        METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY...24439
        METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY...24439
      REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY...24441
        METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY...24441
        METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY...24443
      REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY...24445
        METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY...24445
        METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY...24446
      REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR...24448
        METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR...24448
        METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR...24448
      REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR...24450
        METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR...24450
        METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR...24451
      REMOVE AND INSTALL KDPF TEMPERATURE SENSOR...24452
        METHOD FOR REMOVING KDPF TEMPERATURE SENSOR...24452
        METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR...24455
      REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR...24458
        METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR...24458
        METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR...24461
      REMOVE AND INSTALL SCR TEMPERATURE SENSOR...24464
        METHOD FOR REMOVING SCR TEMPERATURE SENSOR...24464
        METHOD FOR INSTALLING SCR TEMPERATURE SENSOR...24467
      REMOVE AND INSTALL AMMONIA SENSOR...24470
        METHOD FOR REMOVING AMMONIA SENSOR...24470
        METHOD FOR INSTALLING AMMONIA SENSOR...24471
      REMOVE AND INSTALL SCR OUTLET NOx SENSOR...24473
        METHOD FOR REMOVING SCR OUTLET NOx SENSOR...24473
        METHOD FOR INSTALLING SCR OUTLET NOx SENSOR...24474
      REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY...24476
        METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY...24476
        METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY...24477
  60 MAINTENANCE STANDARD...24479
    CONTENTS...24480
    ABBREVIATION LIST...24482
    ENGINE AND COOLING SYSTEM...24488
      MAINTENANCE STANDARD OF ENGINE MOUNT...24488
      MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP...24489
        MAINTENANCE STANDARD OF SERVO VALVE OF BRAKE AND COOLING FAN PUMP...24491
      MAINTENANCE STANDARD OF COOLING FAN MOTOR...24492
    POWER TRAIN...24494
      MAINTENANCE STANDARD OF DRIVE SHAFT...24494
      MAINTENANCE STANDARD OF TORQUE CONVERTER...24495
      MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV...24497
      MAINTENANCE STANDARD OF TRANSMISSION...24498
        MAINTENANCE STANDARD OF F, R CLUTCH...24503
        MAINTENANCE STANDARD OF 1ST, 4TH CLUTCH...24504
        MAINTENANCE STANDARD OF 2ND, 3RD CLUTCH...24505
      MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE...24506
      MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV...24507
      MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE...24508
      MAINTENANCE STANDARD OF FRONT AXLE...24509
      MAINTENANCE STANDARD OF REAR AXLE...24510
      MAINTENANCE STANDARD OF FRONT CONVENTIONAL DIFFERENTIAL...24511
      MAINTENANCE STANDARD OF REAR CONVENTIONAL DIFFERENTIAL...24512
      MAINTENANCE STANDARD OF FRONT LIMITED SLIP DIFFERENTIAL...24513
      MAINTENANCE STANDARD OF REAR LIMITED SLIP DIFFERENTIAL...24515
      MAINTENANCE STANDARD OF FINAL DRIVE...24517
    STEERING SYSTEM...24519
      MAINTENANCE STANDARD OF STEERING COLUMN...24519
      MAINTENANCE STANDARD OF STEERING PUMP...24520
        MAINTENANCE STANDARD OF SERVO VALVE OF STEERING PUMP...24523
      MAINTENANCE STANDARD OF STEERING VALVE...24524
      MAINTENANCE STANDARD OF STEERING CYLINDER...24526
      MAINTENANCE STANDARD OF SECONDARY STEERING PUMP...24528
    BRAKE SYSTEM...24529
      MAINTENANCE STANDARD OF CHARGE VALVE...24529
      MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR...24531
      MAINTENANCE STANDARD OF FRONT BRAKE...24532
      MAINTENANCE STANDARD OF REAR BRAKE...24533
      MAINTENANCE STANDARD OF PARKING BRAKE...24534
      MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE...24535
      MAINTENANCE STANDARD OF FLOW PRIORITY VALVE...24536
      MAINTENANCE STANDARD OF BRAKE COOLING PUMP...24537
      MAINTENANCE STANDARD OF BRAKE COOLING STRAINER...24538
    UNDERCARRIAGE AND FRAME...24539
      MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN...24539
    HYDRAULIC SYSTEM...24544
      MAINTENANCE STANDARD OF HYDRAULIC TANK...24544
      MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP...24545
        MAINTENANCE STANDARD OF SERVO VALVEWORK OF EQUIPMENT PUMP...24548
      MAINTENANCE STANDARD OF POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP...24550
      MAINTENANCE STANDARD OF CONTROL VALVE...24551
      MAINTENANCE STANDARD OF STABILIZER VALVE...24563
      MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE...24564
    WORK EQUIPMENT...24565
      MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE...24565
      MAINTENANCE STANDARD OF BUCKET...24568
      MAINTENANCE STANDARD OF LIFT CYLINDER...24569
      MAINTENANCE STANDARD OF BUCKET CYLINDER...24570
  80 APPENDIX...24571
    CONTENTS...24572
    ABBREVIATION LIST...24574
    AIR CONDITIONER SYSTEM...24580
      PRECAUTIONS FOR REFRIGERANT...24580
      AIR CONDITIONER COMPONENT...24581
      SPECIFICATIONS OF AIR CONDITIONER...24583
      CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE...24584
      OUTLINE OF REFRIGERATION CYCLE...24585
    COMPONENT PARTS OF AIR CONDITIONER SYSTEM...24587
      AIR CONDITIONER UNIT...24587
        CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT...24587
        FUNCTION OF AIR CONDITIONER UNIT...24588
      COMPONENT PARTS OF AIR CONDITIONER UNIT...24589
        FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT...24589
        FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT...24589
        FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT...24590
        FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT...24590
        FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT...24590
        FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT...24590
        FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT...24590
        FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT...24591
        FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...24591
        FUNCTION OF DUAL PRESSURE SWITCH...24591
      AIR CONDITIONER CONTROLLER...24592
        STRUCTURE OF AIR CONDITIONER CONTROLLER...24592
      COMPRESSOR...24593
        STRUCTURE OF COMPRESSOR...24593
        SPECIFICATIONS OF COMPRESSOR...24593
        FUNCTION OF COMPRESSOR...24593
      CONDENSER...24594
        STRUCTURE OF CONDENSER...24594
        SPECIFICATIONS OF CONDENSER...24594
        FUNCTION OF CONDENSER...24594
      RECEIVER DRIER...24595
        STRUCTURE OF RECEIVER DRIER...24595
        SPECIFICATIONS OF RECEIVER DRIER...24595
        FUNCTION OF RECEIVER DRIER...24595
      SENSORS FOR AIR CONDITIONER SYSTEM...24596
        FUNCTION OF SUNLIGHT SENSOR...24596
        FUNCTION OF AMBIENT TEMPERATURE SENSOR...24596
    EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER...24597
    CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER...24599
    AIR CONDITIONER SYSTEM DIAGRAM...24602
      INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER...24603
        FUNCTION OF AIR CONDITIONER CONTROLLER...24604
    INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS...24605
    TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION...24611
    HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR...24612
    CHECK TEMPERATURE CONTROL FUNCTION...24613
      METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION...24613
    TEST VENT (MODE) CHANGEOVER...24615
      METHOD FOR TESTING VENT (MODE) CHANGEOVER...24615
    TESTING FRESH/RECIRC AIR CHANGEOVER...24617
      METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER...24617
    TEST EVAPORATOR TEMPERATURE SENSOR...24619
    TEST RELAYS...24621
      METHOD FOR TESTING RELAYS...24621
    AIR CONDITIONER TROUBLESHOOTING CHART 1...24623
    AIR CONDITIONER TROUBLESHOOTING CHART 2...24624
    FAILURE CODE [879AKA]...24627
    FAILURE CODE [879AKB]...24629
    FAILURE CODE [879BKA]...24631
    FAILURE CODE [879BKB]...24633
    FAILURE CODE [879CKA]...24635
    FAILURE CODE [879CKB]...24637
    FAILURE CODE [879DKZ]...24639
    FAILURE CODE [879EMC]...24641
    FAILURE CODE [879FMC]...24644
    A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)...24647
    A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)...24650
    A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)...24653
    A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER...24657
    TROUBLESHOOTING USING GAUGE PRESSURE...24659
    CONNECTION OF SERVICE TOOL...24662
      METHOD FOR CONNECTING SERVICE TOOL...24663
    PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS...24664
    HANDLE COMPRESSOR OIL...24666
  90 CIRCUIT DIAGRAMS...24669
    CONTENTS...24670
    ABBREVIATION LIST...24671
    HYDRAULIC CIRCUIT DIAGRAM...24677
      SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM...24677
      HYDRAULIC CIRCUIT DIAGRAM...24681
      POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM...24682
      HYDRAULIC OIL PRESSURE OF BRAKE COOLING SYSTEM...24684
      HYDRAULIC AUTO-GREASING DIAGRAM...24686
    ELECTRICAL CIRCUIT DIAGRAM...24687
      SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM...24687
      ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/10)...24691
      ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/10)...24692
      ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/10)...24693
      ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/10)...24694
      ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/10)...24695
      ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/10)...24696
      ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/10)...24697
      ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/10)...24698
      ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/10)...24699
      ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (10/10)...24700
      ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (1/8)...24701
      ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (2/8)...24702
      ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (3/8)...24703
      ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (4/8)...24704
      ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (5/8)...24705
      ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (6/8)...24706
      ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (7/8)...24707
      ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (8/8)...24708
      ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (1/9)...24709
      ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (2/9)...24710
      ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (3/9)...24711
      ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (4/9)...24712
      ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (5/9)...24713
      ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (6/9)...24714
      ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (7/9)...24715
      ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (8/9)...24716
      ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (9/9)...24717
  INDEX...24718
VEBM440101 - Wheel Loader WA380-6 Shop Manual...24740
  VEBM440101 WA380-6...24740
  00 Index and foreword...24742
    Composition of shop manual...24743
    Table of contents...24745
    Index and foreword...24756
      Safety notice...24757
      How to read the shop manual...24762
      Explanation of terms for maintenance standard...24764
      Handling electric equipment and hydraulic component...24766
      How to read electric wire code...24778
      Precautions when carrying out operation...24781
      Method of disassembling and connecting push-pull type coupler...24784
      Standard tightening torque table...24787
      Conversion table...24791
  01 Specification...24796
    Specification and technical data...24798
      Specification dimension drawing...24798
      Specifications...24799
      Weight table...24803
      Table of fuel, coolant and lubricants...24805
  10 Structure, function and maintenance standard...24806
    Engine and cooling system...24807
      Engine mount and transmission mount...24807
      Cooling system...24808
      Cooling fan pump...24809
      Cooling fan motor...24817
    Power train...24826
      Power train...24826
      Power train system diagram...24827
      Drive shaft...24829
      Power train piping diagram...24830
      Torque converter...24831
      Transmission...24839
      Flow control valve...24856
      Valve assembly...24857
      ECMV...24858
      Main relief valve and torque converter relief valve...24865
      Axle...24867
      Differential...24869
      Limited slip differential...24874
      Final drive...24881
    Steering system...24885
      Steering piping diagram...24885
      Steering column...24886
      Steering pump...24887
      Steering valve...24898
      Orbit-roll valve...24913
      Stop valve...24917
      Steering relief valve...24918
      Steering cylinder...24919
      Emergency steering motor...24921
      Emergency steering pump...24922
    Brake system...24925
      Brake piping diagram...24925
      Charge valve...24926
      Brake valve...24933
      Accumulator (for brake)...24938
      Brake...24939
      Parking brake control...24944
      Parking brake...24945
      Parking brake solenoid valve...24947
      Emergency parking brake release valve...24949
    Undercarriage and frame...24951
      Axle mount and center hinge pin...24951
      Tires...24955
    Hydraulic system, Part 1...24957
      Hydraulic piping diagram...24957
      Work equipment control lever linkage...24960
      Hydraulic tank...24961
      Power train pump...24963
      Work equipment pump...24964
      Work equipment control valve...24975
      CLSS...24989
      Each function and operation of each valve...24993
    Hydraulic system, Part 2...25017
      PPC valve...25017
      Stabilizer valve...25023
      Accumulator (for PPC circuit)...25028
      Accumulator (for ECSS)...25029
    Work equipment...25031
      Work equipment linkage...25031
      Bucket...25033
      Bucket positioner and boom kick-out...25034
      Work equipment cylinder...25040
    Cab and its attachments...25044
      Cab...25044
      Air conditioner...25045
    Electrical system, Part 1...25059
      Machine monitor system...25059
      Machine monitor...25064
    Electrical system, Part 2...25087
      Electrical system (Transmission controller system)...25087
      Transmission controller...25121
    Electrical system, Part 3...25125
      Electric transmission control...25125
      Kickdown switch and hold switch...25129
      KOMTRAX terminal system...25131
      Engine starting circuit...25133
      Engine stopping circuit...25135
      Preheating circuit...25136
      Engine power mode selector circuit...25137
      Engine output derating function...25138
      Automatic warm-up function...25138
      Parking brake circuit...25139
      Sensor...25141
    Standard service value table...25151
      Standard service value table for engine...25151
      Standard service value table for chassis...25152
  20 Standard value table...25150
    Standard service value table...25151
  30 Testing and adjusting...25160
    Testing and adjusting, Part 1...25162
      Tools for testing, adjusting, and troubleshooting...25162
      Measuring engine speed...25165
      Measuring exhaust gas color...25167
      Adjusting valve clearance...25169
      Measuring compression pressure...25171
      Measuring blow-by pressure...25174
      Measuring engine oil pressure...25175
      Measuring intake air (boost) pressure...25176
      Handling fuel system equipment...25177
      Releasing residual pressure in fuel system...25177
      Measuring fuel pressure...25178
      Measuring fuel return rate and leakage...25180
      Bleeding air from fuel circuit...25183
      Testing leakage in fuel system...25185
      Handling reduced cylinder mode operation...25186
      Handling no-injection cranking operation...25186
      Handling controller voltage circuit...25187
      Testing and adjusting air conditioner compressor belt tension...25188
      Adjusting transmission speed sensor...25189
      Measuring directional lever...25190
      Measuring and adjusting power train oil pressure...25191
      Procedure for flushing torque converter and transmission hydraulic circuit...25206
      Method of moving machine when transmission valve is broken...25207
      Testing and adjusting steering stop valve...25209
      Testing and adjusting steering wheel...25211
      Testing steering oil pressure...25213
      Bleeding air from steering circuit...25216
    Testing and adjusting, Part 2...25220
      Testing hydraulic drive fan...25220
      Bleeding air from hydraulic drive fan circuit...25222
      Measuring brake pedal...25224
      Measuring brake performance...25225
      Testing and adjusting accumulator charge pressure...25226
      Testing wheel brake oil pressure...25227
      Measuring wear of wheel brake disc...25229
      Bleeding air from wheel brake circuit...25230
      Releasing residual pressure in brake accumulator circuit...25231
      Testing parking brake performance...25232
      Measuring parking brake oil pressure...25233
      Testing wear of parking brake disc...25235
      Method of releasing parking brake manually...25236
      Measuring and adjusting work equipment control lever...25237
      Measuring and adjusting work equipment PPC oil pressure...25238
      Measuring and adjusting work equipment oil pressure...25241
      Bleeding air from work equipment circuit...25245
      Releasing residual pressure in work equipment circuit...25246
      Testing and adjusting bucket positioner...25247
      Testing and adjusting boom kick- out...25249
      Checking proximity switch operation pilot lamp...25250
      Procedure for testing diodes...25251
      Preparation work for troubleshooting for electric system...25252
      How to start operation of KOMTRAX terminal...25257
      Lamp display of KOMTRAX terminal...25262
      Adjusting machine monitor...25265
      Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor...25266
    Testing and adjusting, Part 3...25269
      Special functions of machine monitor (EMMS)...25269
      Pm-click inspection table...25328
  40 Troubleshooting...25330
    General information on troubleshooting...25331
      Points to remember when troubleshooting...25331
      Sequence of events in troubleshooting...25332
      Testing before troubleshooting...25333
      Classification and procedures of troubleshooting...25334
      Connection table for connector pin numbers...25337
      T-branch box and T-branch adapter table...25360
    Troubleshooting by failure code (Display of code), Part 1...25366
      Failure codes list...25366
      Before carrying out troubleshooting for electrical system...25373
      Information contained troubleshooting table...25376
      Failure code [1500L0] (TORQFLOW transmission: Double meshing)...25378
      Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)...25379
      Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)...25381
      Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)...25383
      Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)...25385
      Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)...25387
      Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)...25389
      Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)...25391
      Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)...25393
      Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)...25395
      Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)...25397
      Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)...25399
      Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)...25401
      Failure code [2F00MA] (Parking brake: Malfunction)...25403
    Troubleshooting by failure code (Display of code), Part 2...25409
      Failure code [2G43ZG] (Accumulator: Low oil pressure)...25409
      Failure code [AA1ANX] (Air cleaner: Clogging)...25411
      Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)...25413
      Failure code [AB00MA] (Alternator: Malfunction)...25415
      Failure code [B@BAZG] (Rotation derating by low engine oil pressure)...25417
      Failure code [B@BAZK] (Engine oil: Low level)...25418
      Failure code [B@BCNS] (Coolant: Overheating)...25419
      Failure code [B@BCZK] (Coolant: Low level)...25421
      Failure code [B@C7NS] (Brake oil: Overheating)...25423
      Failure code [b@CENS] (Torque converter oil: Overheating)...25425
      Failure code [B@CENS] (Torque converter oil: Overheating)...25427
      Failure code [B@HANS] (Hydraulic oil: Overheating)...25429
      Failure code [CA111] (Abnormality in engine controller)...25431
      Failure code [CA115] (Engine Ne or Bkup speed sensor error)...25432
      Failure code [CA122] (Charge pressure sensor high error)...25433
      Failure code [CA123] (Charge pressure sensor low error)...25435
      Failure code [CA131] (Throttle sensor high error)...25437
      Failure code [CA132] (Throttle sensor low error)...25439
      Failure code [CA144] (Coolant sensor high error)...25441
      Failure code [CA145] (Coolant sensor low error)...25443
      Failure code [CA153] (Charge temperature sensor high error)...25445
      Failure code [CA154] (Charge temperature sensor low error)...25447
      Failure code [CA155] (Derating of speed by abnormally high charge temperature)...25449
      Failure code [CA187] (Sensor power supply 2 low error)...25451
      Failure code [CA221] (Atmospheric pressure sensor high error)...25453
      Failure code [CA222] (Atmospheric sensor low error)...25455
      Failure code [CA227] (Sensor power supply 2 high error)...25457
    Troubleshooting by failure code (Display of code), Part 3...25460
      Failure code [CA234] (Engine overspeed)...25460
      Failure code [CA238] (Ne speed sensor power supply error)...25461
      Failure code [CA271] (PCV1 Short circuit)...25462
      Failure code [CA272] (PCV1 Disconnection)...25463
      Failure code [CA322] (Injector #1 (L/B #1) open/short error)...25465
      Failure code [CA323] (Injector #5 (L/B #5) open/short error)...25467
      Failure code [CA324] (Injector #3 (L/B #3) open/short error)...25469
      Failure code [CA325] (Injector #6 (L/B #6) open/short error)...25471
      Failure code [CA331] (Injector #2 (L/B #2) open/short error)...25473
      Failure code [CA332] (Injector #4 (L/B #4) open/short error)...25475
      Failure code [CA342] (Calibration code inconsistency)...25477
      Failure code [CA351] (Injectors drive circuit error)...25478
      Failure code [CA352] (Sensor power supply 1 low error)...25480
      Failure code [CA386] (Sensor power supply 1 high error)...25482
      Failure code [CA428] (Abnormally high level in water sensor)...25483
      Failure code [CA429] (Abnormally low level in water sensor)...25485
      Failure code [CA431] (Idle validation switch error)...25487
      Failure code [CA432] (Idle validation action error)...25489
      Failure code [CA435] (Engine oil pressure switch error)...25491
      Failure code [CA441] (Battery voltage low error)...25492
      Failure code [CA442] (Battery voltage high error)...25495
      Failure code [CA449] Common rail pressure high error 2...25497
      Failure code [CA451] (Common rail pressure sensor high error)...25498
      Failure code [CA452] (Common rail pressure sensor low error)...25500
      Failure code [CA488] (Derating of torque by abnormally high charge temperature)...25502
      Failure code [CA553] (Common rail pressure high error 1)...25503
      Failure code [CA559] (Supply pump pressure very low error)...25504
      Failure code [CA689] (Engine Ne speed sensor error)...25505
      Failure code [CA731] (Engine Bkup speed sensor phase error)...25507
      Failure code [CA757] (All continuous data lost error)...25508
      Failure code [CA778] (Engine Bkup speed sensor error)...25511
      Failure code [CA1117] (Partial engine controller data loss error)...25513
      Failure code [CA1633] (KOMNET datalink timeout error)...25516
    Troubleshooting by failure code (Display of code), Part 4...25520
      Failure code [CA2185] (Throttle sensor supply voltage high error)...25520
      Failure code [CA2186] (Throttle sensor power supply low error)...25521
      Failure code [CA2249] (Supply pump pressure very low error 2)...25522
      Failure code [CA2311] (Abnormality in IMV solenoid)...25523
      Failure code [CA2555] (Intake heater relay disconnection error)...25525
      Failure code [CA2556] (Intake heater relay short circuit error)...25527
      Failure code [D150KA] (Emergency steering relay: Disconnection)...25529
      Failure code [D150KB] (Emergency steering relay: Short circuit)...25531
      Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)...25533
      Failure code [D160KA] (Backup lamp relay: Disconnection)...25535
      Failure code [D160KB] (Backup lamp relay: Short circuit)...25537
      Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)...25539
      Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)...25541
      Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)...25543
      Failure code [D192KA] (ECSS solenoid: Disconnection)...25545
      Failure code [D192KB] (ECSS solenoid: Short circuit)...25546
      Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)...25547
      Failure code [D5ZHKA] (Terminal C signal: Disconnection)...25548
      Failure code [D5ZHKB] (Terminal C signal: Short circuit)...25552
      Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)...25556
      Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)...25559
      Failure code [DAF3KK] (Machine monitor: Low source voltage (input))...25561
      Failure code [DAF5KP] (Machine monitor: Low output voltage)...25563
      Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))...25566
      Failure code [DAQ0KK] (Transmission controller: Low source voltage)...25568
      Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)...25570
      Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))...25571
      Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)...25573
    Troubleshooting by failure code (Display of code), Part 5...25576
      Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system))...25576
      Failure code [DAQRMA] (Transmission controller option setting: Malfunction)...25578
      Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)...25579
      Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)...25582
      Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system))...25583
      Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)...25585
      Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time...25587
      Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time...25589
      Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time...25591
      Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time...25593
      Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time...25595
      Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time...25597
      Failure code [DD1GLD] Load meter mode selector switch (+/-): Switch is kept pressed for long time...25599
      Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)...25601
      Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)...25603
      Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)...25605
      Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)...25607
    Troubleshooting by failure code (Display of code), Part 6...25613
      Failure code [DDK3KA] (Right FNR switch: Disconnection)...25613
      Failure code [DDK6KA] (FNR lever switch: Disconnection)...25616
      Failure code [DDK6KB] (FNR lever switch: Short circuit)...25619
      Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)...25621
      Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)...25623
      Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)...25625
      Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)...25627
      Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)...25629
      Failure code [DF10KA] (Transmission shift lever switch: Disconnected)...25631
      Failure code [DF10KB] (Transmission shift lever switch: Short circuit)...25635
      Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)...25637
      Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)...25639
      Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)...25641
      Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)...25643
      Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)...25645
      Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)...25647
    Troubleshooting by failure code (Display of code), Part 7...25651
      Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)...25651
      Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)...25653
      Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)...25655
      Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)...25657
      Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)...25659
    Troubleshooting by failure code (Display of code), Part 8...25663
      Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)...25663
      Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)...25665
      Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)...25667
      Failure code [DV00KB] (Alarm buzzer: Short circuit)...25669
    Troubleshooting by failure code (Display of code), Part 9...25673
      Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)...25673
      Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)...25674
      Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)...25675
      Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)...25677
      Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)...25678
      Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)...25679
      Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)...25681
      Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)...25683
      Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)...25685
      Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)...25687
      Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)...25689
    Troubleshooting by failure code (Display of code), Part 10...25695
      Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)...25695
      Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)...25697
      Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)...25699
      Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)...25701
      Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)...25703
      Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)...25705
      Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)...25707
      Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)...25709
      Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)...25711
      Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)...25713
      Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)...25715
      Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)...25717
      Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)...25719
      Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)...25721
      Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)...25723
      Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)...25725
    Troubleshooting of electrical system (E-mode)...25730
      Before carrying out troubleshooting for electrical system...25730
      Information in troubleshooting table...25733
      E-1 Engine does not start...25734
      E-2 Wiper does not operate...25741
      E-3 Windshield washer does not operate...25745
      E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off...25749
      E-5 Working lamp does not light up or go off...25757
      E-6 Turn signal lamp and hazard lamp do not light up or go off...25762
      E-7 Brake lamp does not light or it keeps lighting up...25768
      E-8 Backup lamp does not light or it keeps lighting up...25770
      E-9 Backup buzzer does not sound or it keeps sounding...25772
      E-10 Horn does not sound or it keeps sounding...25774
      E-11 Alarm buzzer does not sound or it keeps sounding...25777
      E-12 Air conditioner does not operate or stop...25779
      E-13 The KOMTRAX system does not work properly...25782
    Troubleshooting of hydraulic and mechanical system (H-mode)...25786
      Method of using troubleshooting chart...25786
      Table of failure modes and causes...25789
      H-1 The machine does not start...25793
      H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]...25795
      H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]...25796
      H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted...25797
      H-5 Shocks are large at the times of starting and shifting gear...25799
      H-6 Time lag is large at the times of starting and shifting gear...25801
      H-7 The torque converter oil temperature is high...25803
      H-8 Steering does not turn...25804
      H-9 Steering does not turn [Machine with joystick steering (if equipped)]...25805
      H-10 Steering response is low...25806
      H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]...25807
      H-12 Steering is heavy...25808
      H-13 When machine turns, it shakes or makes large shocks...25809
      H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]...25810
      H-15 The wheel brake does not work or does not work well...25811
      H-16 The wheel brake is not released or it drags...25812
      H-17 The parking brake does not work or does not work well...25813
      H-18 The parking brake is not released or it drags (including emergency release system)...25814
      H-19 Lift arm does not rise...25815
      H-20 Lift arm speed is low or rising force of lift arm is insufficient...25816
      H-21 When rising, the lift arm comes to move slowly at specific height...25817
      H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)...25817
      H-23 Hydraulic drifts of the lift arm is large...25817
      H-24 The lift arm wobbles during operation...25817
      H-25 Bucket does not tilt back...25818
      H-26 Bucket speed is low or tilting back force is insufficient...25819
      H-27 The bucket comes to operate slowly in the midst of tilting-back...25820
      H-28 The bucket cylinder cannot hold down the bucket...25820
      H-29 Hydraulic drifts of the bucket is large...25820
      H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”)...25820
      H-31 Lift arm and bucket control levers do not move smoothly and are heavy...25821
      H-32 During operation of the machine, engine speed lowers remarkably or engine stalls...25822
      H-33 Large shock is made when work equipment starts and stops...25822
      H-34 When work equipment circuit is relieved singly, other work equipment moves...25822
      H-35 ECSS does not operate, and pitching, bouncing occur...25823
    Troubleshooting of engine (S-mode)...25826
      Method of using troubleshooting chart...25826
      S-1 Engine does not start easily...25829
      S-2 Engine does not start...25830
      S-3 Engine does not pick up smoothly...25833
      S-4 Engine stops during operations...25834
      S-5 Engine does not rotate smoothly...25835
      S-6 Engine lacks output (or lacks power)...25836
      S-7 Exhaust smoke is black (Incomplete combustion)...25837
      S-8 Oil consumption is excessive (or exhaust smoke is blue)...25838
      S-9 Engine oil becomes contaminated quickly...25839
      S-10 Fuel consumption is excessive...25840
      S-11 Coolant contains oil (blows back or reduces)...25841
      S-12 Oil pressure drops...25842
      S-13 Oil level rises (Water, fuel in oil)...25843
      S-14 Coolant temperature rises too high (Overheating)...25844
      S-15 Abnormal noise is made...25845
      S-16 Vibration is excessive...25846
  50 Disassembly and assembly...25848
    General information on disassembly and assembly...25849
      How to read this manual...25849
      Coating materials list...25851
      Special tools list...25854
    Engine and cooling system...25857
      Removal and installation of fuel supply pump assembly...25857
      Removal and installation of fuel injector assembly...25859
      Removal and installation of cylinder head assembly...25864
      Removal and installation of engine hood...25873
      Removal and installation of radiator assembly...25875
      Removal and installation of air aftercooler...25877
      Removal and installation of hydraulic oil cooler assembly...25879
      Removal and installation of engine assembly...25881
      Removal and installation of cooling fan and fan motor assembly...25886
      Removal and installation of fuel tank assembly...25889
    Power train...25893
      Removal and installation of torque converter and transmission assembly...25893
      Disassembly and assembly of torque converter assembly (Standard specification)...25899
      Disassembly and assembly of torque converter assembly (Lockup specification)...25903
      Disassembly and assembly of transmission assembly...25909
      Disassembly and assembly of transmission clutch pack assembly...25924
      Disassembly and assembly of parking brake assembly...25940
      Removal and installation of front axle assembly...25945
      Removal and installation of rear axle assembly...25947
      Disassembly and assembly of axle housing...25950
      Disassembly and assembly of differential assembly...25959
    Steering system...25973
      Removal and installation of steering demand valve assembly...25973
    Brake system...25977
      Removal and installation of parking brake discs and plates...25977
    Undercarriage and frame...25981
      Removal and installation of center hinge pin...25981
      Removal and installation of counterweight...25989
    Hydraulic system...25993
      Removal and installation of work equipment control valve assembly...25993
      Removal and installation of power train pump and work equipment pump assembly...25995
      Removal and installation of steering pump and cooling fan pump assembly...25996
      Removal and installation of hydraulic tank assembly...25997
    Work equipment...26001
      Removal and installation of work equipment assembly...26001
      Disassembly and assembly of hydraulic cylinder assembly...26005
    Cab and its attachments...26015
      Removal and installation of operator's cab and floor frame assembly...26015
      Removal and installation of operator's cab glass (stuck glass)...26018
      Removal and installation of air conditioner unit assembly...26026
    Electrical system...26031
      Removal and installation of engine controller assembly...26031
  90 Diagrams and drawings...26032
    Hydraulic diagrams and drawings...26032
      Hydraulic diagrams and drawings...26033
        Power train hydraulic circuit diagram...26033
      Hydraulic circuit diagram...26036
    Electrical diagrams and drawings...26040
      Electrical circuit diagram (1/2)...26040
      Electrical circuit diagram (2/2)...26041
      Connector arrangement diagram...26042
VEBM440102 - Wheel Loader WA380-6 Shop Manual...26043
  Cover...26043
  00 Index and foreword...26045
    Index...26045
      Composition of shop manual...26046
      Table of contents...26048
    Foreword and general information...26063
      Safety notice...26064
      How to read the shop manual...26069
      Explanation of terms for maintenance standard...26071
      Handling of electric equipment and hydraulic component...26073
      Handling of connectors newly used for engines...26082
      How to read electric wire code...26085
      Precautions when carrying out operation...26088
      Method of disassembling and connecting push-pull type coupler...26091
      Standard tightening torque table...26094
      Conversion table...26098
  01 Specification...26103
    Specification and technical data...26103
      Specification dimension drawing...26105
      Specifications...26106
      Weight table...26110
      Table of fuel, coolant and lubricants...26112
  10 Structure, function and maintenance standard...26115
    Engine and cooling system...26115
      Engine mount and transmission mount...26116
      Cooling system...26117
      Cooling fan pump...26118
      Cooling fan motor...26126
    Power train...26133
      Power train...26135
      Power train system diagram...26136
      Drive shaft...26138
      Power train piping diagram...26139
      Torque converter...26140
      Transmission...26148
      Flow control valve...26165
      Valve assembly...26166
      ECMV...26167
      Main relief valve and torque converter relief valve...26174
      Axle...26176
      Differential...26178
      Limited slip differential...26183
      Final drive...26190
    Steering system...26193
      Steering piping diagram...26195
      Steering column...26196
      Steering pump...26197
      Steering valve...26209
      Orbit-roll valve...26224
      Stop valve...26232
      Steering relief valve...26233
      Steering cylinder...26234
      Emergency steering motor...26236
      Emergency steering pump...26237
      Joystick steering lever linkage...26238
      Steering electric lever...26239
      Joystick EPC valve...26240
    Brake system...26241
      Brake piping diagram...26242
      Charge valve...26243
      Brake valve...26250
      Accumulator (for brake)...26255
      Brake...26256
      Parking brake control...26261
      Parking brake...26262
      Parking brake solenoid valve...26264
      Emergency parking brake release valve...26266
    Undercarriage and frame...26267
      Axle mount and center hinge pin...26268
      Tires...26272
    Hydraulic system, Part 1...26273
      Hydraulic piping diagram...26274
      Work equipment control lever linkage...26277
      Hydraulic tank...26280
      Power train pump...26282
      Work equipment pump...26283
      Work equipment control valve...26294
      CLSS...26308
      Each function and operation of each valve...26312
    Hydraulic system, Part 2...26335
      PPC valve...26336
      Stabilizer valve...26342
      Accumulator (for PPC circuit)...26348
      Accumulator (for ECSS)...26349
      Work equipment PPC cut-off solenoid valve...26350
    Work equipment...26353
      Work equipment linkage...26354
      Bucket...26356
      Bucket positioner and boom kick-out...26357
      Work equipment cylinder...26363
    Cab and its attachments...26365
      Cab...26367
      Air conditioner...26368
    Electrical system, Part 1...26385
      Machine monitor system...26386
      Machine monitor...26390
    Electrical system, Part 2...26423
      Electrical system (Transmission controller system)...26424
      Transmission controller...26470
      Electrical system (Work equipment controller system)...26472
      Work equipment controller...26478
    Electrical system, Part 3...26481
      Electric transmission control...26484
      Kickdown switch and hold switch...26488
      Load meter cancel switch and load meter subtotal switch...26488
      Multi-function knob...26489
      Joystick steering knob...26490
      KOMTRAX terminal system...26492
      Engine starting circuit...26494
      Engine stopping circuit...26496
      Preheating circuit...26497
      Engine power mode selector circuit...26498
      Engine output derating function...26499
      Automatic warm-up function...26499
      Parking brake circuit...26500
      Sensor...26502
    Central Lubrication System (CLS)...26511
      Function of central lubrication system (CLS)...26512
      Auto-grease pump...26512
      Changing the lubrication interval times...26513
      Operating the central lubrication system...26514
      Display and control unit...26515
      LED-display...26515
      Push buttons...26515
      Three-digit LED display...26516
      Check central lubrication system, fill up grease...26517
  20 Standard value table...26519
    Standard service value table...26519
      Standard service value table for engine...26520
      Standard service value table for chassis...26521
  30 Testing and adjusting...26529
    Testing and adjusting, Part 1...26529
      Tools for testing, adjusting, and troubleshooting...26531
      Testing engine speed...26538
      Testing exhaust gas color...26540
      Adjusting valve clearance...26542
      Testing compression pressure...26544
      Testing blow-by pressure...26547
      Testing engine oil pressure...26548
      Testing intake air (boost) pressure...26549
      Handling fuel system equipment...26550
      Releasing residual pressure in fuel system...26550
      Testing fuel pressure...26551
      Testing fuel delivery, return and leak amount...26553
      Bleeding air from fuel circuit...26556
      Testing leakage in fuel system...26557
      Handling reduced cylinder mode operation...26558
      Handling no-injection cranking operation...26558
      Handling controller voltage circuit...26559
      Testing and adjusting air conditioner compressor belt tension...26560
      Replacing alternator belt...26561
      Adjusting transmission speed sensor...26562
      Testing directional lever...26563
      Testing and adjusting power train oil pressure...26564
      Procedure for flushing torque converter and transmission hydraulic circuit...26579
      Method of moving machine when transmission valve is broken...26580
      Testing and adjusting steering stop valve...26582
      Testing and adjusting steering wheel...26584
      Testing and adjusting steering oil pressure...26586
      Bleeding air from steering circuit...26589
    Testing and adjusting, Part 2...26591
      Testing hydraulic drive fan...26593
      Bleeding air from hydraulic drive fan circuit...26595
      Testing brake pedal...26597
      Testing brake performance...26598
      Testing and adjusting accumulator charge pressure...26599
      Testing wheel brake oil pressure...26600
      Testing wear of wheel brake disc...26602
      Bleeding air from wheel brake circuit...26603
      Releasing residual pressure in brake accumulator circuit...26604
      Testing parking brake performance...26605
      Testing parking brake oil pressure...26606
      Testing wear of parking brake disc...26608
      Method of releasing parking brake manually...26609
      Testing and adjusting work equipment control lever...26610
      Testing and adjusting work equipment PPC oil pressure...26611
      Testing and adjusting work equipment oil pressure...26614
      Bleeding air from work equipment circuit...26618
      Releasing residual pressure in work equipment circuit...26619
      Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator...26620
      Testing and adjusting bucket positioner...26626
      Testing and adjusting boom kick-out...26628
      Checking proximity switch operation pilot lamp...26629
      Procedure for testing diodes...26630
      Preparation work for troubleshooting for electric system...26631
      How to start operation of KOMTRAX terminal...26636
      Lamp display of KOMTRAX terminal...26641
    Testing and adjusting, Part 3...26645
      Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor...26647
      Special functions of machine monitor (EMMS)...26649
      Pm-clinic inspection table...26718
  40 Troubleshooting...26721
    Failure code table and fuse locations...26721
      Failure code table...26722
      Fuse locations...26732
    General information on troubleshooting...26735
      Points to remember when troubleshooting...26736
      Sequence of events in troubleshooting...26737
      Testing before troubleshooting...26738
      Classification and procedures of troubleshooting...26739
      Information contained in troubleshooting table...26742
      Connection table for connector pin numbers...26744
      T- branch box and T- branch adapter table...26780
      “ * ” Shows not T-adapter but socket...26782
    Troubleshooting by failure code (Display of code), Part 1...26783
      Failure code [1500L0] (TORQFLOW transmission: Double meshing)...26785
      Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)...26786
      Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)...26788
      Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)...26790
      Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)...26792
      Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)...26794
      Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)...26796
      Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)...26798
      Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)...26800
      Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)...26802
      Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)...26804
      Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)...26806
      Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)...26808
      Failure code [2F00MA] (Parking brake: Malfunction)...26810
      Failure code [2G43ZG] (Accumulator: Low oil pressure)...26812
      Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)...26814
    Troubleshooting by failure code (Display of code), Part 2...26817
      Failure code [AA1ANX] (Air cleaner: Clogging)...26820
      Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)...26822
      Failure code [AB00MA] (Alternator: Malfunction)...26824
      Failure code [B@BAZG] (Rotation derating by low engine oil pressure)...26826
      Failure code [B@BAZK] (Engine oil: Low level)...26827
      Failure code [B@BCNS] (Coolant: Overheating)...26828
      Failure code [B@BCZK] (Coolant: Low level)...26830
      Failure code [B@BEBF] (Water in fuel error)...26832
      Failure code [B@C7NS] (Brake oil: Overheating)...26834
      Failure code [b@CENS] (Torque converter oil: Overheating)...26836
      Failure code [B@CENS] (Torque converter oil: Overheating)...26838
      Failure code [B@HANS] (Hydraulic oil: Overheating)...26840
      Failure code [CA111] (Abnormality in engine controller)...26842
      Failure code [CA115] (Engine Ne or Bkup speed sensor error)...26843
      Failure code [CA122] (Charge pressure sensor high error)...26844
      Failure code [CA123] (Charge pressure sensor low error)...26846
      Failure code [CA131] (Throttle sensor high error)...26848
      Failure code [CA132] (Throttle sensor low error)...26850
      Failure code [CA144] (Coolant sensor high error)...26852
      Failure code [CA145] (Coolant sensor low error)...26854
      Failure code [CA153] (Charge temperature sensor high error)...26856
      Failure code [CA154] (Charge temperature sensor low error)...26858
      Failure code [CA155] (Derating of speed by abnormally high charge temperature)...26860
      Failure code [CA187] (Sensor power supply 2 low error)...26862
      Failure code [CA221] (Atmospheric pressure sensor high error)...26864
      Failure code [CA222] (Atmospheric sensor low error)...26866
      Failure code [CA227] (Sensor power supply 2 high error)...26868
      Failure code [CA234] (Engine overspeed)...26869
      Failure code [CA238] (Ne speed sensor power supply error)...26870
    Troubleshooting by failure code (Display of code), Part 3...26871
      Failure code [CA271] (IMV/PCV1 Short circuit)...26873
      Failure code [CA272] (IMV/PCV1 Disconnection)...26874
      Failure code [CA322] (Injector #1 open/short error)...26876
      Failure code [CA323] (Injector #5 open/short error)...26878
      Failure code [CA324] (Injector #3 open/short error)...26880
      Failure code [CA325] (Injector #6 open/short error)...26882
      Failure code [CA331] (Injector #2 open/short error)...26884
      Failure code [CA332] (Injector #4 open/short error)...26886
      Failure code [CA342] (Calibration code inconsistency)...26888
      Failure code [CA351] (Injectors drive circuit error)...26890
      Failure code [CA352] (Sensor power supply 1 low error)...26892
      Failure code [CA386] (Sensor power supply 1 high error)...26894
      Failure code [CA428] (Abnormally high level in water sensor)...26895
      Failure code [CA429] (Abnormally low level in water sensor)...26896
      Failure code [CA431] (Idle validation switch error)...26897
      Failure code [CA432] (Idle validation action error)...26900
      Failure code [CA435] (Engine oil pressure switch error)...26902
      Failure code [CA441] (Battery voltage low error)...26903
      Failure code [CA442] (Battery voltage high error)...26906
      Failure code [CA449] Common rail pressure high error 2...26908
      Failure code [CA451] (Common rail pressure sensor high error)...26910
      Failure code [CA452] (Common rail pressure sensor low error)...26912
      Failure code [CA488] (Derating of torque by abnormally high charge temperature)...26914
      Failure code [CA553] (Common rail pressure high error 1)...26915
      Failure code [CA559] (Supply pump pressure very low error)...26916
      Failure code [CA689] (Engine Ne speed sensor error)...26918
      Failure code [CA731] (Engine Bkup speed sensor phase error)...26920
      Failure code [CA757] (All continuous data lost error)...26921
      Failure code [CA778] (Engine Bkup speed sensor error)...26924
      Failure code [CA1633] (KOMNET datalink timeout error)...26926
      Failure code [CA2185] (Throttle sensor power supply voltage high error)...26928
      Failure code [CA2186] (Throttle sensor power supply voltage low error)...26929
    Troubleshooting by failure code (Display of code), Part 4...26931
      Failure code [CA2249] (Supply pump pressure very low error 2)...26933
      Failure code [CA2311] (Abnormality in IMV solenoid)...26934
      Failure code [CA2555] (Intake heater relay disconnection error)...26936
      Failure code [CA2556] (Intake heater relay short circuit error)...26938
      Failure code [D150KA] (Emergency steering relay: Disconnection)...26940
      Failure code [D150KB] (Emergency steering relay: Short circuit)...26942
      Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)...26944
      Failure code [D160KA] (Backup lamp relay: Disconnection)...26946
      Failure code [D160KB] (Backup lamp relay: Short circuit)...26948
      Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)...26950
      Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)...26952
      Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)...26954
      Failure code [D192KA] (ECSS solenoid: Disconnection)...26956
      Failure code [D192KB] (ECSS solenoid: Short circuit)...26957
      Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)...26958
      Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection)...26960
      Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit)...26962
      Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line)...26964
      Failure code [D5ZHKA] (Terminal C signal: Disconnection)...26967
      Failure code [D5ZHKB] (Terminal C signal: Short circuit)...26971
      Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)...26974
      Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)...26979
      Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)...26982
      Failure code [DAF3KK] (Machine monitor: Low source voltage (input)...26984
      Failure code [DAF5KP] (Machine monitor: Low output voltage)...26986
      Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system)...26990
    Troubleshooting by failure code (Display of code), Part 5...26993
      Failure code [DAQ0KK] (Transmission controller: Low source voltage)...26996
      Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)...26998
      Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)...26999
      Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)...27001
      Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)...27002
      Failure code [DAQRMA] (Transmission controller option setting: Malfunction)...27005
      Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)...27006
      Failure code [DB90KK] Work equipment controller: Low source voltage (input)...27008
      Failure code [DB90KT] Work equipment controller: Abnormality in controller...27010
      Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)...27011
      Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range...27013
      Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)...27016
      Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)...27017
      Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)...27019
      Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation)...27020
      Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time...27024
      Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time...27026
      Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time...27028
      Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time...27030
      Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time...27032
      Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time...27034
      Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time...27036
      Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time...27038
      Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time...27040
      Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)...27042
      Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)...27044
      Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)...27046
      Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)...27048
    Troubleshooting by failure code (Display of code), Part 6...27051
      Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)...27054
      Failure code [DDK3KA] (Right FNR switch: Disconnection)...27056
      Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)...27059
      Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)...27062
      Failure code [DDK6KA] (FNR lever switch: Disconnection)...27064
      Failure code [DDK6KB] (FNR lever switch: Short circuit)...27068
      Failure code [DDS5KA] (Steering pressure switch: Disconnected)...27070
      Failure code [DDS5KB] (Steering pressure switch: Grounded)...27072
      Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)...27074
      Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)...27076
      Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)...27078
      Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)...27080
      Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)...27082
      Failure code [DF10KA] (Transmission shift lever switch: Disconnected)...27084
      Failure code [DF10KB] (Transmission shift lever switch: Short circuit)...27088
      Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)...27090
      Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)...27092
      Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)...27094
      Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)...27096
      Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)...27098
      Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)...27100
      Failure code [DH21KA] (Loader pump pressure sensor: Disconnection)...27102
      Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short)...27104
    Troubleshooting by failure code (Display of code), Part 7...27107
      Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)...27110
      Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)...27112
      Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)...27114
      Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)...27116
      Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)...27118
      Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)...27120
      Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)...27123
      Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)...27126
      Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)...27129
      Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)...27132
      Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)...27135
      Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)...27138
      Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)...27141
      Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)...27144
      Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)...27147
    Troubleshooting by failure code (Display of code), Part 8...27151
      Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)...27153
      Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)...27156
      Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)...27158
      Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)...27162
      Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)...27164
      Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)...27168
      Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)...27170
      Failure code [DKA0L0] (Lift arm angle sensor: Dislocation of sensor)...27172
      Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)...27174
      Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)...27176
      Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)...27178
      Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)...27180
      Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)...27182
      Failure code [DV00KB] (Alarm buzzer: Short circuit)...27184
      Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)...27186
      Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)...27188
      Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)...27190
      Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)...27192
      Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)...27193
      Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)...27194
      Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)...27196
      Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)...27197
      Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)...27198
    Troubleshooting by failure code (Display of code), Part 9...27201
      Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)...27203
      Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)...27204
      Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)...27206
      Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)...27208
      Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)...27209
      Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)...27210
      Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)...27212
      Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)...27214
      Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)...27216
      Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)...27218
      Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)...27220
      Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)...27222
      Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)...27224
      Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)...27226
      Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)...27228
      Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)...27230
      Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)...27232
      Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)...27234
      Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)...27236
      Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)...27237
      Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)...27238
      Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)...27240
      Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)...27242
      Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)...27244
      Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)...27246
      Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)...27248
      Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)...27250
    Troubleshooting by failure code (Display of code), Part 10...27253
      Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)...27256
      Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)...27258
      Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)...27260
      Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)...27262
      Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)...27264
      Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)...27266
      Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)...27268
      Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)...27270
      Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)...27272
      Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)...27274
      Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)...27276
      Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)...27278
      Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)...27280
      Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)...27282
      Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)...27284
      Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)...27286
      Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)...27288
      Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)...27290
      Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)...27292
      Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)...27294
      Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)...27296
      Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine)...27298
      Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode)...27301
    Troubleshooting of electrical system (E-mode)...27305
      Installing positions of fuses...27307
      Information in troubleshooting table...27310
      E-1 Engine does not start...27311
      E-2 Wiper does not operate...27318
      E-3 Windshield washer does not operate...27322
      E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off...27325
      E-5 Working lamp does not light up or go off...27333
      E-6 Turn signal lamp and hazard lamp do not light up or go off...27338
      E-7 Brake lamp does not light or it keeps lighting up...27344
      E-8 Backup lamp does not light or it keeps lighting up...27346
      E-9 Backup buzzer does not sound or it keeps sounding...27348
      E-10 Horn does not sound or it keeps sounding...27350
      E-11 Alarm buzzer does not sound or it keeps sounding...27352
      E-12 Air conditioner does not operate or stop...27354
      E-13 The KOMTRAX system does not work properly...27357
      E-14 When kick-down switch is turned ON, kick-down operation does not start...27360
      E-15 When hold switch is pressed, holding operation does not start...27362
      E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied...27364
      E-17 Transmission cut-off mode cannot be set or reset...27366
      E-18 Transmission cut-off set cannot be reset...27368
      E-19 FNR switch mode cannot be set or reset...27370
      E-20 Fan reverse function cannot be used or reset...27372
      E-21 Discharge from loader pump does not rise from minimum level...27374
      E-22 ECSS function cannot be used or reset...27376
      E-23 When parking brake is turned ON, parking brake indicator lamp does not light up...27378
      E-24 When emergency brake operates, brake oil pressure caution lamp does not operate...27382
      E-25 Air cleaner clogging indicator lamp does not light up...27384
      E-26 Radiator coolant level caution lamp does not light up...27386
      E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light up...27387
      E-28 Torque converter oil temperature gauge does not rise and torque converter oil temperature caution lamp does not light up...27388
      E-29 Steering oil pressure caution lamp does not light up...27390
      E-30 Abnormality in t switch (panel switch 1) input...27392
      E-31 Abnormality in U switch (panel switch 2) input...27394
      E-32 Abnormality in < switch (panel switch 3) input...27396
      E-33 Abnormality in > switch (panel switch 4) input...27398
    Troubleshooting of hydraulic and mechanical system (H-mode)...27401
      Method of using troubleshooting chart...27403
      Table of failure modes and causes...27406
      H-1 The machine does not start...27410
      H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]...27412
      H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]...27413
      H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted...27414
      H-5 Shocks are large at the times of starting and shifting gear...27416
      H-6 Time lag is large at the times of starting and shifting gear...27418
      H-7 The torque converter oil temperature is high...27420
      H-8 Steering does not turn...27421
      H-9 Steering does not turn [Machine with joystick steering (if equipped)]...27422
      H-10 Steering response is low...27423
      H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]...27424
      H-12 Steering is heavy...27425
      H-13 When machine turns, it shakes or makes large shocks...27426
      H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]...27427
      H-15 The wheel brake does not work or does not work well...27428
      H-16 The wheel brake is not released or it drags...27429
      H-17 The parking brake does not work or does not work well...27430
      H-18 The parking brake is not released or it drags (including emergency release system)...27431
      H-19 Lift arm does not rise...27432
      H-20 Lift arm speed is low or rising force of lift arm is insufficient...27433
      H-21 When rising, the lift arm comes to move slowly at specific height...27434
      H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)...27434
      H-23 Hydraulic drifts of the lift arm is large...27434
      H-24 The lift arm wobbles during operation...27434
      H-25 Bucket does not tilt back...27435
      H-26 Bucket speed is low or tilting back force is insufficient...27436
      H-27 The bucket comes to operate slowly in the midst of tilting-back...27437
      H-28 The bucket cylinder cannot hold down the bucket...27437
      H-29 Hydraulic drifts of the bucket is large...27437
      H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”)...27437
      H-31 Lift arm and bucket control levers do not move smoothly and are heavy...27438
      H-32 During operation of the machine, engine speed lowers remarkably or engine stalls...27439
      H-33 Large shock is made when work equipment starts and stops...27439
      H-34 When work equipment circuit is relieved singly, other work equipment moves...27439
      H-35 ECSS does not operate, and pitching, bouncing occur...27440
    Troubleshooting of engine (S-mode)...27441
      Method of using troubleshooting charts...27443
      S-1 Engine does not start easily...27446
      S-2 Engine does not start...27447
      S-3 Engine does not pick up smoothly...27450
      S-4 Engine stops during operations...27451
      S-5 Engine does not rotate smoothly...27452
      S-6 Engine lacks output (or lacks power)...27453
      S-7 Exhaust smoke is black (Incomplete combustion)...27454
      S-8 Oil consumption is excessive (or exhaust smoke is blue)...27455
      S-9 Engine oil becomes contaminated quickly...27456
      S-10 Fuel consumption is excessive...27457
      S-11 Coolant contains oil (blows back or reduces)...27458
      S-12 Oil pressure drops...27459
      S-13 Oil level rises (Water, fuel in oil)...27460
      S-14 Coolant temperature rises too high (Overheating)...27461
      S-15 Abnormal noise is made...27462
      S-16 Vibration is excessive...27463
    Troubleshooting of Central Lubrication System (CLS)...27465
      Trouble...27466
      Troubleshooting FPS...27467
      Troubleshooting...27468
      Pump Faults...27468
      Replace pump element...27470
      Check power supply...27470
      Changing the control unit:...27470
      Troubleshooting – grease system faults...27471
      Venting of the system...27472
      General assembly advice...27473
  50 Disassembly and assembly...27475
    General information on disassembly and assembly...27475
      How to read this manual...27476
      Coating materials list...27478
      Special tools list...27481
      Sketches of special tools...27484
    Engine and cooling system...27491
      Removal and installation of fuel supply pump assembly...27492
      Removal and installation of fuel injector assembly...27495
      Removal and installation of cylinder head assembly...27502
      Removal and installation of engine hood assembly...27513
      Removal and installation of radiator assembly...27515
      Removal and installation of air aftercooler...27517
      Removal and installation of hydraulic oil cooler assembly...27519
      Removal and installation of engine assembly...27521
      Removal and installation of engine front oil seal assembly...27526
      Removal and installation of engine rear oil seal assembly...27529
      Removal and installation of cooling fan and fan motor assembly...27532
      Removal and installation of fuel tank assembly...27535
    Power train...27537
      Removal and installation of torque converter and transmission assembly...27538
      Disassembly and assembly of torque converter assembly (Standard specification)...27544
      Disassembly and assembly of torque converter assembly (Lockup specification)...27548
      Disassembly and assembly of transmission assembly...27554
      Disassembly and assembly of transmission clutch pack assembly...27570
      Disassembly and assembly of parking brake assembly...27588
      Removal and installation of front axle assembly...27597
      Removal and installation of rear axle assembly...27599
      Disassembly and assembly of axle housing...27602
      Disassembly and assembly of differential assembly...27611
    Steering system...27631
      Removal and installation of steering valve assembly...27632
    Brake system...27635
      Removal and installation of parking brake discs and plates...27636
    Undercarriage and frame...27639
      Removal and installation of center hinge pin...27640
      Removal and installation of counterweight...27648
    Hydraulic system...27651
      Removal and installation of work equipment control valve assembly...27652
      Removal and installation of power train pump and work equipment pump assembly...27655
      Removal and installation of steering pump and cooling fan pump assembly...27656
      Removal and installation of hydraulic tank assembly...27657
    Work equipment...27661
      Removal and installation of work equipment assembly...27662
      Disassembly and assembly of hydraulic cylinder assembly...27666
    Cab and its attachments...27675
      Removal and installation of operator's cab and floor frame assembly...27676
      Removal and installation of operator's cab glass (stuck glass)...27679
      Disassembly and assembly of operator's seat assembly (Standard specification)...27687
      Disassembly and assembly of operator's seat assembly (Manufactured by GRAMMER)...27696
      Removal and installation of air conditioner unit assembly...27729
    Electrical system...27733
      Removal and installation of engine controller assembly...27734
  90 Diagrams and drawings...27735
    Hydraulic diagrams and drawings...27735
      Power train hydraulic circuit diagram...27736
      Automatic greasing circuit diagram...27738
    Electrical diagrams and drawings...27743
    Connector list and tables...27761
      Connector list...27762
      Connector diagram 1/3...27772
      Connector diagram 2/3...27774
      Connector diagram 3/3...27774
VEBM460104 - Wheel Loader WA380-3 Shop Manual...27776
  Contents...27777
    01 General...27784
      Up to SN WA380H20500...27786
      Dimensions and weights...27786
      Dimensions and weights high-lift...27787
      Specifications...27788
      Weight table...27791
      List of lubricant and water...27792
      SN WA380H20501 and up...27793
      Dimensions and weights...27793
      Specifications...27794
      Weight table...27797
      List of lubricant and water...27798
      Outlines of service...27800
      General view of controls and gauges...27803
      Torque list...27805
    10 Structure and function...27806
      Power train...27808
      Power train system...27809
      Torque converter, transmission piping...27811
      Transmission hydraulic circuit diagram...27812
      Torque converter...27814
      Torque converter oil filter...27816
      Transmission...27818
      Transmission control valve...27828
      Upper valve...27829
      Transmission solenoid valve...27831
      Pilot reducing valve...27832
      Main relief valve...27833
      Torque converter outlet port valve...27834
      Priority valve...27835
      Directional selector valve...27836
      H-L selector valve and range selector valve...27837
      Emergency manuel spool...27839
      Electronic control modulation valve (ECMV)...27840
      Pilot oil filter...27843
      Accumulator valve...27844
      Flow control valve...27846
      Check valve...27847
      Drife shaft...27848
      Axle...27849
      Differential...27851
      Final drive...27856
      Axle mount, center hinge pin...27857
      Steering piping...27860
      Steering control, orbit roll...27861
      Orbit roll valve...27862
      Steering valve...27863
      Overload relief valve...27864
      Steering relief valve...27866
      Operation of demand valve...27867
      Emergency steering...27874
      Brake piping...27884
      Park brake and foot brake circuits...27885
      Brake valve...27886
      Accumulator charge valve...27891
      Accumulator for brake system...27895
      Brake circuit diagram...27897
      Brake...27909
      Parking brake control...27911
      Parking brake...27912
      Parking brake valve...27913
      Hydraulic piping...27914
      Work equipment hydraulic system diagram...27915
      Work equipment lever linkage...27925
      Hydraulic tank...27926
      Oil filter bypass valve...27927
      PPC valve...27928
      Operation of PPC valve...27933
      PPC relief valve...27936
      Accumulator (for PPC valve)...27937
      Main control valve (up to H20383)...27938
      Relief valve (up to H20383)...27942
      Safety valve with suction (up to H20383)...27943
      Suction valve (up to H20383)...27944
      Main control valve (from  H20384 up to H20836)...27945
      Safety valve with suction (H20384 and up)...27947
      Antcavitation valve (H20384 and up)...27948
      Safety valve (H20384 and up)...27948
      Main control valve (H20837 and up)...27949
      Operation of cut-off valve (up to H20383)...27951
      Work equipment valve operation...27953
      Hydraulic safety system (up to H20836)...27959
      Hydraulic safety system location (up to H20836)...27960
      Hydraulic safety valve (up to H20836)...27961
      Work equipment linkage...27962
      Bucket...27964
      Bucket positioner and boom kick-out...27965
      Wiring diagrams...27972
      Machine monitor system...28016
      Transmission auot-shift control system...28023
      Transmission controller...28028
      ECSS (ALS electronic)...28030
      Sensors...28040
      Engine starting circuit...28045
      Engine stop circuit...28046
      Preheating circuit...28047
      Electric transmission...28052
      Combination switch...28053
      Kick-down, hold switch...28055
      Kick-down electric circuit diagram...28056
      Transmission cut-off function...28061
      Parking brake: transmission neutralizer...28062
      Air conditioner...28064
    20 Testing and adjusting...28118
      Standard value table for engine...28119
      Standard value table for chassis...28121
      Tesz certificate...28125
      Standard value table for electrical system...28129
      Tools for testing, adjusting and troubleshooting...28142
      Adjusting valve clearance...28144
      Measuring compression pressure...28148
      Measuring blow-by pressure...28150
      Testing and adjusting fuel injection timing...28152
      Measuring intake air pressure ...28154
      Measuring engine oil pressure...28155
      Measuring engine speed...28156
      Measuring stall speed...28157
      Testing the fan belt tension...28159
      Measuring turbocharger clearance...28160
      Turbocharger wastegate actuator - visual inspection...28161
      Turbocharger wastegate actuator - functional checking...28163
      Adjusting valve clearance...28164
      Measuring compression pressure...28165
      Measuring blow-by pressure...28166
      Testing and adjusting fuel injection timing...28167
      Measuring exhaust color...28170
      Measuring inkake air pressure (boost pressure)...28171
      Measuring exhaust gas pressure...28172
      Measuring engine oil pressure...28173
      Measuring engine speed...28174
      Testing and adjusting fan belt tension...28175
      Method for adjusting engine stop cable...28176
      Measuring accelerator pedal...28178
      Basic adjustment of accelerator pedal...28180
      Measuring operating force, travel of speed lever...28182
      Measuring stall speed...28183
      Measuring torque converter, transmission, parking brake oil pressure...28185
      Method of operating emergency manual spool...28187
      Measuring clearance between tire and wheel...28189
      Measuring steering oil pressure...28192
      Measuring operating force, travel of brake pedal...28194
      Measuring brake performance...28195
      Testing brake oil pressure...28196
      Testing for brake disk wear...28197
      Bleeding air from brake system...28198
      Measuring parking brake performance...28199
      Manual release method for parking brake...28200
      Testing wear of parking brake disk...28201
      Measuring work equipment control lever...28202
      Measuring work equipment hydraulic pressure...28204
      Measuring PPC-valve pressure...28206
      Measuring work equipment...28210
      Testing and adjusting bucket positioner...28212
      Testing and adjusting boom kick-out...28213
      Adjusting main monitor...28215
      Gas side test and topping up gas pressure...28216
      Hydraulic accumulator...28218
      Troubleshooting...28220
        POINTS TO REMEMBER WHEN TROUBLESHOOTING...28221
        SEQUENCE OF EVENTS IN TROUBLESHOOTING...28222
        PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...28223
        HANDLING CONNECTORS...28230
        CHECKS BEFORE TROUBLESHOOTING...28231
        METHOD OF USING TROUBLESHOOTING CHARTS...28232
        CONNECTOR TYPES AND MOUNTING LOCATION...28241
        CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...28250
        TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...28258
        TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)...28278
        TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)...28316
        TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...28336
        TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)...28374
        TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (T MODE)...28394
        TROUBLESHOOTING OF ECSS (D MODE)...28418
    30 Disassembly and assembly...28432
      Precautions when carrying out operations...28434
      Special tool list...28437
      Starting motor...28440
      Alternator...28441
      Engine oil cooler...28442
      Fuel injection pump...28443
      Water pump...28447
      Turbocharger...28448
      Nozzle holder...28449
      Thermostat...28450
      Cylinder head...28451
      Radiator...28458
      Engine...28462
      Torque converter charging pump...28468
      Torque converter, transmission...28470
      Torque converter...28475
      Transmission...28480
      Transmission clutch pack...28504
      Transmission control valve...28524
      Transmission accumulator valve...28532
      Drive shaft...28534
      Front axle...28539
      Rear axle...28540
      Differential...28546
      Axle housing...28561
      Center hinge pin...28578
      Steering gear...28585
      Steering valve...28588
      Steering cylinder...28605
      Brake valve...28607
      Right brake valve (tandem)...28609
      Left brake valve (single)...28611
      Parking brake disc...28613
      Hydraulic tank...28616
      Hydraulic filter...28619
      Hydraulic, steering, switch, PPC pump...28620
      Main control valve...28624
      PPC valve...28632
      Bucket cylinder...28637
      Boom cylinder...28640
      Hydraulic cylinder...28642
      Work equipment...28648
      Counterweight...28653
      Fuel tank...28654
      Cab, floor frame...28657
      Cab...28660
      Main monitor...28662
      Maintenance monitor...28664
      Air conditioner unit...28665
      Air conditioner condenser...28671
      Dry receiver...28673
      Air conditioner condenser compressor...28674
    40 Maintenance standard...28676
      Engine mount, transmission mount...28677
      Torque converter charging pump...28678
      Torque converter...28679
      Transmission...28680
      Transmission control valve...28688
      Flow control valve...28692
      Accumulator valve...28693
      Drive shaft...28694
      Differential...28695
      Final drive...28698
      Axle mount...28700
      Center hinge pin...28701
      Steering column...28703
      Steering valve...28704
      Steering cylinder mount...28705
      Brake...28706
      Brake valve...28707
      Parking brake...28710
      Hydraulic pump...28711
      Main control valve...28712
      PPC valve...28716
      Hydraulic cylinder...28717
      Work equipment linkage...28718
      Bucket...28720
      Bucket positioner and boom kick-out...28721
  Diagrams...28722