Komatsu Wheel Loader GALEO WA450-5L, WA480-5L & Log Loader WA450-3LL Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader GALEO WA450-5L, WA480-5L & Log Loader WA450-3LL, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loader GALEO WA450-5L, WA480-5L & Log Loader WA450-3LL 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.
PRODUCT DETAILS:
Total Pages: 3,683 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEBM009601 - Wheel Loader GALEO WA450-5L, WA480-5L Shop Manual.pdf
CEBM009605 - Wheel Loader GALEO WA450-5L, WA480-5L Shop Manual.pdf
SEBM009904 - Log Loader WA450-3LL Shop Manual.pdf
CEAM008901 - Wheel Loader GALEO WA450-5L Operation & Maintenance Manual.pdf
CEAM009001 - Wheel Loader GALEO WA480-5L Operation & Maintenance Manual.pdf
MAIN SECTIONS
CEAM008901 - Wheel Loader GALEO WA450-5L Operation & Maintenance Manual.......2
COVER.......2
INTRODUCTION.......8
FOREWORD.......9
SAFETY INFORMATION.......11
APPROVED AND NON-APPROVED USES.......12
NON-APPROVED.......12
PRODUCT IDENTIFICATION.......13
MACHINE SERIAL NUMBER.......13
ENGINE SERIAL NUMBER AND EMISSION LABEL.......14
SERVICE METER LOCATION.......14
SERIAL NUMBERS AND DEALER INFORMATION.......15
CONTENTS.......16
SAFETY.......28
GENERAL SAFETY RULES AND PRECAUTIONS.......29
GENERAL SAFETY RULES.......29
SAFETY FEATURES.......30
PERSONAL PROTECTIVE EQUIPMENT.......30
UNAUTHORIZED MODIFICATIONS.......31
LEAVING OPERATORS COMPARTMENT.......31
MOUNTING AND DISMOUNTING.......32
WASTE HANDLER APPLICATIONS.......32
FIRE PREVENTION FOR FUEL AND OIL.......33
DUST HAZARD PRECAUTIONS.......33
CRUSH OR PINCH POINT DANGERS.......34
FIRE EXTINGUISHER AND FIRST AID KIT.......34
INSIDE OPERATORS COMPARTMENT.......35
PRECAUTIONS WHEN USING ROPS.......35
PRECAUTIONS FOR ATTACHMENTS.......35
STARTING YOUR WORK OPERATIONS.......36
WORK SITE HAZARDS.......36
AVOIDING DANGEROUS SITUATIONS.......36
WORKING CLEARANCES.......38
RULES FOR ROAD TRAVEL.......39
TRAVELING IN REVERSE.......39
TRAVELING ON ICY OR SNOW-COVERED SURFACES.......39
WORKING ON LOOSE OR UNSTABLE GROUND.......39
TRAVEL ON SLOPES.......40
PARKING THE MACHINE.......41
PRECAUTIONS DURING MAINTENANCE OPERATIONS.......42
WARNING TAGS.......42
EQUIPMENT STORAGE.......42
WORKING UNDER THE MACHINE.......43
USING DROP LAMPS.......43
KEEPING THE MACHINE CLEAN.......44
RUNNING THE MACHINE DURING MAINTENANCE.......44
RULES FOR REFUELING THE MACHINE.......45
COOLING SYSTEM PRECAUTIONS.......45
BATTERY PRECAUTIONS.......46
STARTING THE MACHINE.......46
HIGH PRESSURE HOSES.......47
HIGH TEMPERATURES AREAS.......47
DISPOSAL OF WASTE MATERIALS.......47
INFLATING TIRES.......48
ACCUMULATOR.......48
CRITICAL PARTS.......48
VIBRATIONS TO WHICH THE OPERATOR IS EXPOSED.......48
SAFETY AND WARNING DECALS.......49
LOCATION OF THE SAFETY DECALS.......49
LOCATION OF SAFETY LABELS.......50
SAFETY LABELS.......50
OPERATION.......60
GENERAL VIEW OF MACHINE.......61
OUTSIDE VIEW OF THE MACHINE.......61
INSIDE VIEW OF THE CAB.......62
DESCRIPTION OF ALERTS, GAUGES AND SWITCHED SYSTEMS.......63
INSTRAMENT BEZEL.......63
SWITCH PANELS.......64
DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM.......65
INSTRAMENT BEZEL.......65
TYPES OF WARNING.......66
MACHINE ELECTRONIC MONITORING DISPLAY.......67
MONITOR MODE SELECTOR SWITCHES.......67
MODE SELECTOR SWITCH 1.......68
MODE SELECTOR SWITCH 2.......68
MONITOR DISPLAY INFORMATION.......68
HOUR METER AND ODOMETER DISPLAY.......68
ADJUSTING MONITOR BRIGHTNESS.......69
POGRAMING TELEPHONE NUMBER.......69
ACTION CODE DISPLAY.......69
FAILURE CODE DISPLAY.......70
SERVICE DISPLAY.......71
SELECTING LANGUAGE.......72
EMERGENCY STOP WARNING SYSTEM.......73
BRAKE PRESSURE WARNING LAMP.......73
ENGINE OIL PRESSURE WARNING LAMP.......74
BATTERY CHARGE WARNING LAMP.......74
STEERING OIL PRESSURE WARNING LAMP.......74
CAUTION ALERT WARNING SYSTEM.......75
AXLE OIL TEMPERATURE CAUTION LAMP.......75
TORQUE CONVERTER CAUTION LAMP.......76
COOLANT TEMPERATURE CAUTION LAMP.......76
HYDRAULIC OIL TEMPERATURE CAUTION LAMP.......76
FUEL LEVEL CAUTION LAMP.......76
INSPECTION AND MAINTENANCE ALERT WARNING SYSTEM.......77
ENGINE OIL LEVEL CAUTION LAMP.......77
RADIATOR COOLANT LEVEL CAUTION LAMP.......78
AIR CLEANER CLOGGING CAUTION LAMP.......78
MAINTENANCE CAUTION LAMP.......78
BATTERY ELECTROLYTE LEVEL CAUTION LAMP.......78
MODE ALERT LAMPS.......79
PARKING BRAKE PILOT LAMP.......80
COOLING FAN REVERSE ROTATION PILOT LAMP.......80
EMERGENCY STEERING PILOT LAMP.......80
OUTPUT MODE PILOT LAMP (POWER MODE).......81
PREHEATING PILOT LAMP.......81
JOYSTICK PILOT LAMP.......81
DIRECTIONAL SELECTOR LAMP.......81
SHIFT INDICATOR.......82
AUTO-SHIFT PILOT LAMP.......82
LOCKUP PILOT LAMP.......82
SHIFT HOLD PILOT LAMP.......82
SHIFT LEVER POSITION PILOT LAMP.......83
TURN SIGNAL PILOT LAMP.......83
HEADLAMP HIGH BEAM PILOT LAMP.......83
GAUGE DISPLAY.......84
TORQUE CONVERTER OIL TEMPERATURE GAUGE.......84
ENGINE TEMPERATURE GAUGE.......85
HYDRAULIC TEMPERATURE GAUGE.......85
FUEL GAUGE.......85
SPEEDOMETER.......85
METER DISPLAY PILOT LAMP.......86
MACHINE MONITOR.......86
DISPLAYING ODOMETER.......86
RESET FOR FILTER, OIL REPLACEMENT TIME.......86
ENTERING A TELEPHONE NUMBER.......87
SELECTING A LANGUAGE.......88
ADJUSTING MONITOR BRIGHTNESS.......89
MACHINE SWITCHES AND CONTROLS.......90
SWITCH LOCATION.......90
IGNITION SWITCH.......91
POWER MODE SELECTOR SWITCH.......91
TRANSMISSION MODE SELECTOR SWITCH.......92
TRANSMISSION CUT-OFF SWITCH.......92
TRANSMISSION CUT-OFF SET SWITCH.......93
LAMP SWITCH.......93
TURN SIGNAL LEVER.......93
DIMMER SWITCH.......94
HORN BUTTON.......94
HAZARD LAMP SWITCH.......94
PARKING BRAKE SWITCH.......94
FRONT WORKING LAMP SWITCH.......95
REAR WORKING LAMP SWITCH.......95
MONITOR PANEL MODE SELECTOR SWITCH 1.......96
MONITOR PANEL MODE SELECTOR SWITCH 2.......96
KICKDOWN SWITCH.......96
HOLD SWITCH.......97
FRONT WIPER SWITCH.......97
REAR WIPER SWITCH.......97
CIGARETTE LIGHTER.......98
CAB LAMP SWITCH.......98
REAR DEFROSTER SWITCH.......98
E.C.S.S. SWITCH.......99
EMERGENCY STEERING SWITCH.......99
COOLING FAN REVERSE ROTATION SWITCH.......100
DIRECTIONAL SELECTOR SWITCH.......100
DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH.......101
TORQUE CONVERTER LOCK-UP SWITCH.......101
LOAD METER CANCEL SWITCH.......101
LOAD METER SUBTOTAL SWITCH.......101
EXPLANATION OF RADIO COMPONENTS.......102
POWER SWITCH/VOLUME.......102
TONE CONTROL KNOB.......103
DISPLAY.......103
CLOCK BUTTON/DISPLAYING FREQUENCY.......103
AST.......103
PRESET BUTTON.......104
SEEK.......104
BAND SELECTOR SWITCH.......104
TUNING SWITCH.......104
LISTENING TO THE RADIO.......105
AUTOMATIC TUNING.......105
MANUAL TUNING.......105
SETTING THE PRESET BUTTONS.......105
AUTOMATIC MEMORY.......106
AUTOMATIC SWITCHING RECEPTION OF MONAURAL/STEREO.......106
ADJUSTING THE TIME.......106
PRECAUTIONS WHEN USING.......106
LOCATIONS AND FUNCTION OF AIR CONDITIONER CONTROL PANEL.......107
FAN SWITCH.......108
TEMPERATURE CONTROL SWITCH.......108
MONITOR PANEL.......109
AIR CONDITIONER SWITCH.......109
METHOD OF OPERATION.......109
MANUAL OPERATION.......110
STOPPING MANUAL OPERATION.......111
MODE SELECTOR SWITCH.......111
RECIR/FRESH SELECTOR SWITCH.......111
WHEN NOT USING THE AIR CONDITIONER REGULARLY.......112
COOL BOX.......112
PRECAUTIONS WHEN USING THE COOLING.......112
CONTROL LEVERS, PEDALS.......113
SPEED CONTROL LEVER.......113
DIRECTIONAL LEVER.......115
SPEED CONTROL LEVER STOPPER.......115
SAFETY LOCK LEVER.......116
BUCKET CONTROL LEVER.......116
LIFT ARM CONTROL LEVER.......117
BRAKE PEDAL.......117
ACCELERATOR PEDAL.......118
STEERING TILT LOCK LEVER.......118
SECURITY AND LOCKS.......119
IGNITION KEY LOCKED AREAS.......119
CAB DOOR LOCKS.......119
ENGINE ACCESS DOORS.......119
REAR GRILL.......120
FUEL CAP.......120
PADLOCKED AREAS.......121
BATTERY AND TOOL BOX.......121
TRANSFER CASE.......121
UPPER HOOD ACCESS PANNEL.......121
SAFETY FEATURES.......122
PASSIVE SAFETY FEATURES.......122
ROLL-OVER PROTECTIVE STRUCTURE (ROPS).......122
CAB FRONTAL GUARD (WASTE HANDLER APPLICATION ONLY).......122
BACKUP WARNING ALARM.......122
ACTIVE SAFETY FEATURES.......123
SAFETY BAR.......123
SEAT BELT.......123
EQUIPMENT LOCK LEVER.......124
MACHINE FEATURES.......125
CAB DOORS.......125
OPEN LOCK.......125
ELECTRICAL.......125
FUSE.......125
FUSE CAPACITY AND NAME OF CIRCUIT.......126
SLOW BLOW FUSE.......127
AUXILIARY POWER.......127
MACHINE CAB AND CHASSIS.......128
SEAT ADJUSTMENT.......128
HANDLING CAB WIPER.......130
DUST INDICATOR.......130
GREASE PUMP.......130
PRECAUTIONS BEFORE STARTING WORK OPERATIONS.......131
PRE-OPERATIONAL CHECKS.......131
PERFORM A WALK AROUND CHECK OF YOUR MACHINE.......131
UNDER THE HOOD.......131
CHECK COOLANT LEVEL.......132
CHECK ENGINE OIL LEVEL, ADD OIL.......133
REAR-VIEW MIRROR ADJUSTMENT.......133
IN THE OPERATORS CAB.......134
SEAT BELT ADJUSTMENT.......134
LEVER STAND ADJUSTMENT.......135
LEVER STAND ANGLE ADJUSTMENT.......135
START-UP PROCEDURES.......136
CHECK FUEL LEVEL, ADD FUEL.......136
CHECK THE BRAKE PEDALS.......137
CHECK THE PARKING BRAKE.......137
STARTING THE ENGINE.......138
OPERATIONS AND CHECKS AFTER STARTING ENGINE.......141
BREAKING IN THE MACHINE.......141
NORMAL START-UP AND WARM-UP.......141
STOPPING THE ENGINE.......142
TRAVELING, STOPPING AND PARKING THE MACHINE.......143
TRAVELING.......143
TURNING ON SLOPES.......145
CHANGING GEAR SPEED RANGES.......145
CHANGING DIRECTION.......146
WHEN USING AUTO-SHIFT.......147
USING THE SWITCH TO CHANGE DIRECTION.......147
STOPPING AND PARKING THE MACHINE.......149
TRANSMISSION CUT-OFF SWITCH.......151
ADJUSTING THE TRANSMISSION CUT-OFF.......151
STOPPING WHEN TRANSMISSION CUT-OFF IS ON.......152
TURNING.......152
EMERGENCY STEERING.......153
USING THE EMERGENCY STEERING.......153
EMERGENCY STEERING SELF-CHECK FUNCTION.......154
STARTING YOUR WORK OPERATIONS.......155
WORK EQUIPMENT.......155
LIFT ARM LEVER.......155
BUCKET LEVER.......156
SCOOPING A LOAD OR CUTTING A GRADE.......157
LOADING PILED SOIL OR BLASTED ROCK.......157
CUTTING A GRADE ON LEVEL GROUND.......159
LEVELING OPERATIONS.......160
PUSHING OPERATION.......160
LOAD AND CARRY OPERATIONS.......160
LOADING OPERATIONS.......161
CROSS DRIVE LOADING.......161
V-SHAPE LOADING.......161
PRECAUTIONS WHEN PILING UP LOADS.......161
PRECAUTIONS DURING OPERATION.......162
PERMISSIBLE WATER DEPTH.......162
IF WHEEL BRAKE DOES NOT WORK.......162
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.......162
BRAKING ON DOWNHILL SLOPE.......162
IF THE ENGINE STOPS.......162
PRECAUTIONS WHEN DRIVING THE MACHINE.......163
PRECAUTIONS REGARDING BRAKE FUNCTION.......163
WORK EQUIPMENT AND MACHINE POSTURE.......164
ADJUSTING BUCKET.......164
BOOM KICKOUT ADJUSTMENT.......164
BUCKET POSITIONER ADJUSTMENT.......165
BUCKET LEVEL INDICATOR.......165
TRANSPORTING THE MACHINE.......166
LOADING AND SECURING THE MACHINE.......166
LIFTING THE MACHINE.......167
LIFTING LOCATIONS AND PROCEDURES.......167
USING WIRE ROPE.......168
PRE LIFTING PROCEDURES.......168
TOWING THE MACHINE.......170
COLD WEATHER OPERATION.......171
FUEL AND LUBRICANTS.......171
COOLANT.......171
PRECAUTIONS AFTER COMPLETION OF WORK.......171
AFTER COLD WEATHER.......171
WARMING UP THE STEERING.......171
MAINTENANCE.......172
GUIDES TO MAINTENANCE.......173
CHECK SERVICE METER.......173
KOMATSU GENUINE REPLACEMENT PARTS.......173
KOMATSU GENUINE OILS.......173
ALWAYS USE CLEAN WASHER FLUID.......173
ALWAYS USE CLEAN OIL AND GREASE.......173
CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS.......173
FUEL STRAINER.......173
WELDING INSTRUCTIONS.......173
DO NOT DROP THINGS INSIDE THE MACHINE.......174
DUSTY WORKSITES.......174
AVOID MIXING OIL.......174
LOCKING INSPECTION COVERS.......174
BLEEDING AIR FROM HYDRAULIC CIRCUIT.......174
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES.......174
CHECKS AFTER INSPECTION AND MAINTENANCE.......175
SYSTEMS TROUBLESHOOTING CHARTS.......176
ELECTRICAL SYSTEM.......176
CHASSIS.......177
ENGINE.......181
OUTLINES OF SERVICE.......183
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.......183
OIL.......183
FUEL.......183
COOLANT.......183
GREASE.......184
PERFORMING KOWA (KOMATSU OIL WEAR ANALYSIS).......184
KOWA ANALYSIS ITEMS.......185
OIL SAMPLING.......185
STORING OIL AND FUEL.......185
FILTERS.......186
OUTLINE OF ELECTRIC SYSTEM.......186
WEAR PARTS LIST.......187
FUEL, COOLANT AND LUBRICANTS.......188
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.......188
LUBRICANT AND COOLANT SUPPLIER RECOMMENDATIONS.......190
STANDARD TIGHTENING TORQUES FOR FASTNERS AND HOSES.......192
TORQUE LIST.......192
CLEANING THE MACHINE.......193
CLEAN TIPS.......193
WASTE HANDLER MACHINE.......193
FAN SOLENOID VALVE.......194
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.......195
MAINTENANCE SCHEDULE CHART.......196
GENERAL MAINTENANCE AND INSPECTION.......196
EVERY 50 HOURS SERVICE.......196
EVERY 100 HOURS SERVICE.......196
EVERY 250 HOURS SERVICE.......196
EVERY 500 HOURS SERVICE.......196
EVERY 1000 HOURS SERVICE.......197
EVERY 2000 HOURS SERVICE.......197
EVERY 4000 HOURS SERVICE.......197
EVERY 8000 HOURS SERVICE.......197
GENERAL MAINTENANCE AND INSPECTION.......198
INITIAL 250 HOURS SERVICE.......198
ENGINE AIR FILTER.......198
CLEANING THE COOLING SYSTEM.......201
TRANSMISSION OIL LEVEL.......203
AXLE OIL LEVEL.......204
CHECK AXLE VENT.......206
AIR CONDITIONER CONDENSER.......206
WINDOW WASHING FLUID LEVEL.......207
CLEANING RADIATOR FINS.......208
CHECKING ELECTRICAL INTAKE AIR HEATER.......209
REPLACE BOLT-ON CUTTING EDGE.......209
REPLACE BUCKET TEETH.......210
REPLACING SLOW-BLOW FUSE.......211
INSPECTION OF TIRES.......212
EVERY SPECIFIC HOURS SERVICE.......214
EVERY 50 HOURS OF SERVICE.......214
DRAIN SEDIMENT FROM FUEL TANK.......214
EVERY 100 HOURS SERVICE.......214
LUBRICATE THE REAR AXLE PIVOT PIN.......214
CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL.......214
CLEANING THE AIR CONDITIONER FRESH AIR FILTER ELEMENT.......215
EVERY 250 HOURS OF SERVICE.......216
CHECK BATTERY ELECTROLYTE LEVEL.......216
CHECK PARKING BRAKE.......218
ALTERNATOR BELT TENSION.......218
AIR CONDITIONER COMPRESSOR BELT TENSION.......218
WHEEL HUB NUTS.......219
AIR CONDITIONER RECIRCULATION FILTER.......219
LUBRICATING POINTS.......220
EVERY 500 HOURS SERVICE.......221
CHANGE THE ENGINE OIL, REPLACE THE ENGINE OIL FILTER CARTRIDGE.......221
REPLACING FUEL FILTER CARTRIDGE.......222
CLEANING THE FUEL STRAINER.......223
EVERY 1000 HOURS SERVICE.......225
CHANGE TRANSMISSION OIL AND FILTER CARTRIDGE, CLEAN STRAINER.......225
CLEAN THE TRANSMISSION CASE VENT.......226
LUBRICATING POINTS.......227
CHECKING PARTS OF TURBOCHARGER.......227
CHECK PLAY OF TURBOCHARGER ROTOR.......227
REPLACE CORROSION RESISTOR CARTRIDGE.......227
EVERY 2000 HOURS SERVICE.......228
CHANGE HYDRAULIC OIL, REPLACE HYDRAULIC OIL FILTER ELEMENT.......228
HYDRAULIC TANK VENT ELEMENT.......230
CHANGE THE AXLE OIL.......231
AIR CONDITIONER RECIRCULATION FILTER.......231
CLEAN PPC CIRCUIT STRAINER.......232
CLEAN THE ENGINE VENT ELEMENT.......232
CHECK ALTERNATOR, STARTER MOTOR.......233
CHECK ENGINE VALVE CLEARANCE.......233
CHECK TURBOCHARGER.......233
CHECK INJECTOR.......233
CHECK ACCUMULATOR GAS PRESSURE.......233
CHECK VIBRATION DAMPER.......233
CHECKING BRAKE DISC WEAR.......234
EVERY 4000 HOURS SERVICE.......235
LUBRICATING POINTS.......235
CHECK WATER PUMP.......236
CHECK AIR CONDITIONER COMPRESSOR.......236
REPLACE INJECTOR NOZZLE TIP.......236
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.......236
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.......236
EVERY 8000 HOURS SERVICE.......237
REPLACE HIGH-PRESSURE PIPING CLAMP.......237
REPLACE FUEL SPRAY PREVENTION CAP.......237
SPECIFICATIONS.......238
SPECIFICATIONS.......239
WA450-5L WITH BOLT-ON CUTTING EDGE.......239
MACHINE DIMENSIONS AND WEIGHTS.......240
TIRES.......240
WORK EQUIPMENT.......241
WEIGHT CHANGES.......242
HYDRAULIC SYSTEM.......242
MACHINE SYSTEMS SPECIFICATIONS.......243
ENGINE.......243
TRANSMISSION.......244
AXLES AND FINAL DRIVES.......244
BRAKES.......244
STEERING SYSTEM.......244
SERVICE REFILL CAPACITIES.......244
OPTIONS, ATTACHMENTS.......246
MONITOR WITH LOAD METER.......247
LOAD METER.......247
SWITCHES.......247
LOAD METER CANCEL SWITCH.......248
LOAD METER SUB TOTAL SWITCH.......248
LOAD METER FUNCTIONS.......249
LOAD METER ADDITION MODE.......249
LOAD METER REMAIN MODE.......250
SELECTION OF DISPLAY FOR TYPE OF LOAD.......250
METHOD OF CALIBRATION (ADJUSTING 0 POINT).......251
DELETING LOAD METER DISPLAY.......251
SPEED DISPLAY.......251
USING LOAD METER DISPLAY.......252
SETTING ADDITION MODE.......252
SETTING THE REMAIN MODE.......253
TOTAL LOAD DATA DISPLAY.......255
STOPPING THE CALCULATION.......256
PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY.......257
PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED.......258
SUBTRACTION FUNCTION.......260
SETTING THE TIME ON THE CLOCK.......263
PRINTER OUTPUT.......265
PRINTOUT MODE.......265
SELECTING THE PRINTOUT MODE.......266
TORQUE CONVERTER LOCK-UP.......267
GENERAL LOCATIONS.......267
TORQUE CONVERTER LOCK-UP SWITCH.......267
TORQUE CONVERTER LOCK-UP PILOT LAMP.......268
METHOD OF OPERATION.......268
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED.......269
TRAVEL SPEED WARNING FUNCTION.......269
TRAVEL SPEED LIMIT FUNCTION.......269
WASTE HANDLER ENGINE COOLING FAN CONTROL SYSTEM.......270
FAN SYSTEM OPERATION.......270
MODE SELECTOR SWITCH.......271
FORWARD/REVERSE TIMER.......271
REVERSE/FORWARD INDICATOR LAMPS.......271
FORWARD SETTING KNOB.......272
REVERSE SETTING KNOB.......272
FORWARD TIME UNIT SELECTOR SWITCH.......273
SCALE FIGURE SELECTOR SWITCH.......273
DIRECTION SELECTOR SWITCH.......274
REVERSE PILOT LAMP.......274
CONTROL BOX.......274
CLEANING RADIATOR AND COOLER FINS.......275
HANDLING JOYSTICK STEERING SYSTEM.......277
EXPLANATION OF COMPONENTS.......277
SHIFT UP, SHIFT DOWN SWITCHES.......277
FNR SWITCH.......278
JOYSTICK STEERING LEVER.......278
JOYSTICK ON/OFF SWITCH.......278
HI/LOW SELECTOR SWITCH.......278
HORN SWITCH.......279
CONSOLE LOCK LEVER.......279
HEIGHT ADJUSTMENT LOCK LEVER.......279
ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER.......279
STRUCTURE AND FUNCTION OF JOYSTICK STEERING.......280
JOYSTICK AND STEERING WHEEL OPERATION.......281
GETTING IN OR OUT OF THE OPERATOR'S CAB.......281
JOYSTICK CONSOLE ADJUSTMENT.......282
JOYSTICK OPERATION.......282
CEAM009001 - Wheel Loader GALEO WA480-5L Operation & Maintenance Manual.......288
COVER.......288
INTRODUCTION.......294
FOREWORD.......295
SAFETY INFORMATION.......297
APPROVED AND NON-APPROVED USES.......298
NON-APPROVED.......298
PRODUCT IDENTIFICATION.......299
MACHINE SERIAL NUMBER.......299
ENGINE SERIAL NUMBER AND EMISSION LABEL.......300
SERVICE METER LOCATION.......300
SERIAL NUMBERS AND DEALER INFORMATION.......301
CONTENTS.......302
SAFETY.......314
GENERAL SAFETY RULES AND PRECAUTIONS.......315
GENERAL SAFETY RULES.......315
SAFETY FEATURES.......316
PERSONAL PROTECTIVE EQUIPMENT.......316
UNAUTHORIZED MODIFICATIONS.......317
LEAVING OPERATORS COMPARTMENT.......317
MOUNTING AND DISMOUNTING.......318
WASTE HANDLER APPLICATIONS.......318
FIRE PREVENTION FOR FUEL AND OIL.......319
DUST HAZARD PRECAUTIONS.......319
CRUSH OR PINCH POINT DANGERS.......320
FIRE EXTINGUISHER AND FIRST AID KIT.......320
INSIDE OPERATORS COMPARTMENT.......321
PRECAUTIONS WHEN USING ROPS.......321
PRECAUTIONS FOR ATTACHMENTS.......321
STARTING YOUR WORK OPERATIONS.......322
WORK SITE HAZARDS.......322
AVOIDING DANGEROUS SITUATIONS.......322
WORKING CLEARANCES.......324
RULES FOR ROAD TRAVEL.......325
TRAVELING IN REVERSE.......325
TRAVELING ON ICY OR SNOW-COVERED SURFACES.......325
WORKING ON LOOSE OR UNSTABLE GROUND.......325
TRAVEL ON SLOPES.......326
PARKING THE MACHINE.......327
PRECAUTIONS DURING MAINTENANCE OPERATIONS.......328
WARNING TAGS.......328
EQUIPMENT STORAGE.......328
WORKING UNDER THE MACHINE.......329
USING DROP LAMPS.......329
KEEPING THE MACHINE CLEAN.......330
RUNNING THE MACHINE DURING MAINTENANCE.......330
RULES FOR REFUELING THE MACHINE.......331
COOLING SYSTEM PRECAUTIONS.......331
BATTERY PRECAUTIONS.......332
STARTING THE MACHINE.......332
HIGH PRESSURE HOSES.......333
HIGH TEMPERATURES AREAS.......333
DISPOSAL OF WASTE MATERIALS.......333
INFLATING TIRES.......334
ACCUMULATOR.......334
CRITICAL PARTS.......334
VIBRATIONS TO WHICH THE OPERATOR IS EXPOSED.......334
SAFETY AND WARNING DECALS.......335
LOCATION OF THE SAFETY DECALS.......335
LOCATION OF SAFETY LABELS.......336
SAFETY LABELS.......336
OPERATION.......346
GENERAL VIEW OF MACHINE.......347
OUTSIDE VIEW OF THE MACHINE.......347
INSIDE VIEW OF THE CAB.......348
DESCRIPTION OF ALERTS, GAUGES AND SWITCHED SYSTEMS.......349
INSTRUMENT BEZEL.......349
SWITCH PANELS.......351
DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM.......352
INSTRUMENT BEZEL.......352
TYPES OF WARNING.......353
MACHINE ELECTRONIC MONITORING DISPLAY.......354
MONITOR MODE SELECTOR SWITCHES.......354
MODE SELECTOR SWITCH 1.......355
MODE SELECTOR SWITCH 2.......355
MONITOR DISPLAY INFORMATION.......355
HOUR METER AND ODOMETER DISPLAY.......355
ADJUSTING MONITOR BRIGHTNESS.......356
PROGRAMMING TELEPHONE NUMBER.......356
ACTION CODE DISPLAY.......356
FAILURE CODE DISPLAY.......357
SERVICE DISPLAY.......358
SELECTING LANGUAGE.......359
EMERGENCY STOP WARNING SYSTEM.......360
BRAKE PRESSURE WARNING LAMP.......360
ENGINE OIL PRESSURE WARNING LAMP.......361
BATTERY CHARGE WARNING LAMP.......361
STEERING OIL PRESSURE WARNING LAMP.......361
CAUTION ALERT WARNING SYSTEM.......362
AXLE OIL TEMPERATURE CAUTION LAMP.......362
TORQUE CONVERTER CAUTION LAMP.......363
COOLANT TEMPERATURE CAUTION LAMP.......363
HYDRAULIC OIL TEMPERATURE CAUTION LAMP.......363
FUEL LEVEL CAUTION LAMP.......363
INSPECTION AND MAINTENANCE ALERT WARNING SYSTEM.......364
ENGINE OIL LEVEL CAUTION LAMP.......364
RADIATOR COOLANT LEVEL CAUTION LAMP.......365
AIR CLEANER CLOGGING CAUTION LAMP.......365
MAINTENANCE CAUTION LAMP.......365
BATTERY ELECTROLYTE LEVEL CAUTION LAMP.......365
MODE ALERT LAMPS.......366
PARKING BRAKE PILOT LAMP.......367
COOLING FAN REVERSE ROTATION PILOT LAMP.......367
EMERGENCY STEERING PILOT LAMP.......367
OUTPUT MODE PILOT LAMP (POWER MODE).......368
PREHEATING PILOT LAMP.......368
JOYSTICK PILOT LAMP.......368
DIRECTIONAL SELECTOR LAMP.......368
SHIFT INDICATOR.......369
AUTO-SHIFT PILOT LAMP.......369
LOCKUP PILOT LAMP.......369
SHIFT HOLD PILOT LAMP.......369
SHIFT LEVER POSITION PILOT LAMP.......370
TURN SIGNAL PILOT LAMP.......370
HEADLAMP HIGH BEAM PILOT LAMP.......370
GAUGE DISPLAY.......371
TORQUE CONVERTER OIL TEMPERATURE GAUGE.......371
ENGINE TEMPERATURE GAUGE.......372
HYDRAULIC TEMPERATURE GAUGE.......372
FUEL GAUGE.......372
SPEEDOMETER.......372
METER DISPLAY PILOT LAMP.......373
MACHINE MONITOR.......373
DISPLAYING ODOMETER.......373
RESET FOR FILTER, OIL REPLACEMENT TIME.......373
ENTERING A TELEPHONE NUMBER.......374
SELECTING A LANGUAGE.......375
ADJUSTING MONITOR BRIGHTNESS.......376
MACHINE SWITCHES AND CONTROLS.......377
SWITCH LOCATION.......377
IGNITION SWITCH.......378
POWER MODE SELECTOR SWITCH.......378
TRANSMISSION MODE SELECTOR SWITCH.......379
TRANSMISSION CUT-OFF SWITCH.......379
TRANSMISSION CUT-OFF SET SWITCH.......380
LAMP SWITCH.......380
TURN SIGNAL LEVER.......380
DIMMER SWITCH.......381
HORN BUTTON.......381
HAZARD LAMP SWITCH.......381
PARKING BRAKE SWITCH.......381
FRONT WORKING LAMP SWITCH.......382
REAR WORKING LAMP SWITCH.......382
MONITOR PANEL MODE SELECTOR SWITCH 1.......383
MONITOR PANEL MODE SELECTOR SWITCH 2.......383
KICKDOWN SWITCH.......383
HOLD SWITCH.......384
FRONT WIPER SWITCH.......384
REAR WIPER SWITCH.......384
CIGARETTE LIGHTER.......385
CAB LAMP SWITCH.......385
REAR DEFROSTER SWITCH.......385
E.C.S.S. SWITCH.......386
EMERGENCY STEERING SWITCH.......386
COOLING FAN REVERSE ROTATION SWITCH.......387
DIRECTIONAL SELECTOR SWITCH.......387
DIRECTIONAL SELECTOR ACTUATION SWITCH.......388
TORQUE CONVERTER LOCK-UP SWITCH.......388
LOAD METER CANCEL SWITCH.......388
LOAD METER SUBTOTAL SWITCH.......388
SOUND SYSTEM.......389
DIGITAL ESPERIA RADIO SERIAL NUMBER A37001 - A37046.......389
POWER SWITCH/VOLUME.......389
TONE CONTROL KNOB.......390
DISPLAY.......390
CLOCK BUTTON/DISPLAYING FREQUENCY.......390
AST.......390
PRESET BUTTON.......391
SEEK.......391
BAND SELECTOR SWITCH.......391
TUNING SWITCH.......391
LISTENING TO THE RADIO.......392
AUTOMATIC TUNING.......392
MANUAL TUNING.......392
SETTING THE PRESET BUTTONS.......392
AUTOMATIC MEMORY.......393
AUTOMATIC SWITCHING RECEPTION OF MONAURAL/STEREO.......393
ADJUSTING THE TIME.......393
BLAUPUNKT CALAIS RADIO SERIAL NUMBER A37047 AND UP.......394
POWER SWITCH/MUTE.......394
VOLUME CONTROL.......395
FMT CONTROL.......395
IR REMOTE CONTROL (OPTIONAL).......395
RDS CONTROL.......395
ML CONTROL.......396
EJECT CASSETTE.......396
CASSETTE COMPARTMENT.......396
FF AND RW BUTTONS.......396
GEO BUTTON.......397
SRC BUTTON.......397
AUDIO BUTTON.......397
MULTIFUNCTION ROCKER SWITCH.......397
MENU BUTTON.......398
KEYPAD 1-5.......398
TRAFFIC.......398
DISPLAY.......398
THEFT PROTECTION.......399
PRECAUTIONS WHEN USING.......399
AIR CONDITIONER CONTROL PANEL.......400
FAN SWITCH.......400
AIR CONDITIONER SWITCH.......401
MODE SELECTOR SWITCH.......401
FRESH/RECIRC SELECTOR SWITCH.......401
EXTERNAL AIR INTAKE.......401
TEMPERATURE CONTROL SWITCH.......402
METHOD OF OPERATION.......402
WHEN NOT USING THE AIR CONDITIONER REGULARLY.......403
COOL BOX.......404
PRECAUTIONS WHEN USING THE AIR CONDITIONER.......404
CONTROL LEVERS, PEDALS.......405
SPEED CONTROL LEVER.......405
DIRECTIONAL LEVER.......407
SPEED CONTROL LEVER STOPPER.......407
SAFETY LOCK LEVER.......408
BUCKET CONTROL LEVER.......408
LIFT ARM CONTROL LEVER.......409
BRAKE PEDAL.......409
ACCELERATOR PEDAL.......410
STEERING TILT LOCK LEVER.......410
SECURITY AND LOCKS.......411
IGNITION KEY LOCKED AREAS.......411
CAB DOOR LOCKS.......411
ENGINE ACCESS DOORS.......411
REAR GRILL.......412
FUEL CAP.......412
PADLOCKED AREAS.......413
BATTERY AND TOOL BOX.......413
TRANSFER CASE.......413
UPPER HOOD ACCESS PANNEL.......413
SAFETY FEATURES.......414
PASSIVE SAFETY FEATURES.......414
ROLL-OVER PROTECTIVE STRUCTURE (ROPS).......414
CAB FRONTAL GUARD (WASTE HANDLER APPLICATION ONLY).......414
BACKUP WARNING ALARM.......414
ACTIVE SAFETY FEATURES.......415
SAFETY BAR.......415
SEAT BELT.......415
EQUIPMENT LOCK LEVER.......416
MACHINE FEATURES.......417
CAB DOORS.......417
OPEN LOCK.......417
ELECTRICAL.......417
FUSE.......417
FUSE CAPACITY AND NAME OF CIRCUIT.......418
SLOW BLOW FUSE.......419
AUXILIARY POWER.......419
MACHINE CAB AND CHASSIS.......420
SEAT ADJUSTMENT.......420
HANDLING CAB WIPER.......422
DUST INDICATOR.......422
GREASE PUMP.......422
PRECAUTIONS BEFORE STARTING WORK OPERATIONS.......423
PRE-OPERATIONAL CHECKS.......423
PERFORM A WALK AROUND CHECK OF YOUR MACHINE.......423
UNDER THE HOOD.......423
CHECK COOLANT LEVEL.......424
CHECK ENGINE OIL LEVEL, ADD OIL.......425
REAR-VIEW MIRROR ADJUSTMENT.......425
IN THE OPERATORS CAB.......426
SEAT BELT ADJUSTMENT.......426
LEVER STAND ADJUSTMENT.......427
LEVER STAND ANGLE ADJUSTMENT.......427
START-UP PROCEDURES.......428
CHECK FUEL LEVEL, ADD FUEL.......428
CHECK THE BRAKE PEDALS.......429
CHECK THE PARKING BRAKE.......429
STARTING THE ENGINE.......430
OPERATIONS AND CHECKS AFTER STARTING ENGINE.......433
BREAKING IN THE MACHINE.......433
NORMAL START-UP AND WARM-UP.......433
STOPPING THE ENGINE.......434
TRAVELING, STOPPING AND PARKING THE MACHINE.......435
TRAVELING.......435
TURNING ON SLOPES.......437
CHANGING GEAR SPEED RANGES.......437
CHANGING DIRECTION.......438
WHEN USING AUTO-SHIFT.......439
USING THE SWITCH TO CHANGE DIRECTION.......439
STOPPING AND PARKING THE MACHINE.......441
TRANSMISSION CUT-OFF SWITCH.......443
ADJUSTING THE TRANSMISSION CUT-OFF.......443
STOPPING WHEN TRANSMISSION CUT-OFF IS ON.......444
TURNING.......444
EMERGENCY STEERING.......445
USING THE EMERGENCY STEERING.......445
EMERGENCY STEERING SELF-CHECK FUNCTION.......446
STARTING YOUR WORK OPERATIONS.......447
WORK EQUIPMENT.......447
LIFT ARM LEVER.......447
BUCKET LEVER.......448
SCOOPING A LOAD OR CUTTING A GRADE.......449
LOADING PILED SOIL OR BLASTED ROCK.......449
CUTTING A GRADE ON LEVEL GROUND.......451
LEVELING OPERATIONS.......452
PUSHING OPERATION.......452
LOAD AND CARRY OPERATIONS.......452
LOADING OPERATIONS.......453
CROSS DRIVE LOADING.......453
V-SHAPE LOADING.......453
PRECAUTIONS WHEN PILING UP LOADS.......453
PRECAUTIONS DURING OPERATION.......454
PERMISSIBLE WATER DEPTH.......454
IF WHEEL BRAKE DOES NOT WORK.......454
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.......454
BRAKING ON DOWNHILL SLOPE.......454
IF THE ENGINE STOPS.......454
PRECAUTIONS WHEN DRIVING THE MACHINE.......455
PRECAUTIONS REGARDING BRAKE FUNCTION.......455
WORK EQUIPMENT AND MACHINE POSTURE.......456
ADJUSTING BUCKET.......456
BOOM KICKOUT ADJUSTMENT.......456
BUCKET POSITIONER ADJUSTMENT.......457
BUCKET LEVEL INDICATOR.......457
TRANSPORTING THE MACHINE.......458
LOADING AND SECURING THE MACHINE.......458
LIFTING THE MACHINE.......459
LIFTING LOCATIONS AND PROCEDURES.......459
USING WIRE ROPE.......460
PRE LIFTING PROCEDURES.......460
TOWING THE MACHINE.......462
COLD WEATHER OPERATION.......463
FUEL AND LUBRICANTS.......463
COOLANT.......463
PRECAUTIONS AFTER COMPLETION OF WORK.......463
AFTER COLD WEATHER.......463
WARMING UP THE STEERING.......463
MAINTENANCE.......464
GUIDES TO MAINTENANCE.......465
CHECK SERVICE METER.......465
KOMATSU GENUINE REPLACEMENT PARTS.......465
KOMATSU GENUINE OILS.......465
ALWAYS USE CLEAN WASHER FLUID.......465
ALWAYS USE CLEAN OIL AND GREASE.......465
CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS.......465
FUEL STRAINER.......465
WELDING INSTRUCTIONS.......465
DO NOT DROP THINGS INSIDE THE MACHINE.......466
DUSTY WORKSITES.......466
AVOID MIXING OIL.......466
LOCKING INSPECTION COVERS.......466
BLEEDING AIR FROM HYDRAULIC CIRCUIT.......466
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES.......466
CHECKS AFTER INSPECTION AND MAINTENANCE.......467
SYSTEMS TROUBLESHOOTING CHARTS.......468
ELECTRICAL SYSTEM.......468
CHASSIS.......469
ENGINE.......473
OUTLINES OF SERVICE.......475
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.......475
OIL.......475
FUEL.......475
COOLANT.......475
GREASE.......476
PERFORMING KOWA (KOMATSU OIL WEAR ANALYSIS).......476
KOWA ANALYSIS ITEMS.......477
OIL SAMPLING.......477
STORING OIL AND FUEL.......477
FILTERS.......478
OUTLINE OF ELECTRIC SYSTEM.......478
WEAR PARTS LIST.......479
FUEL, COOLANT AND LUBRICANTS.......480
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.......480
LUBRICANT AND COOLANT SUPPLIER RECOMMENDATIONS.......482
STANDARD TIGHTENING TORQUES FOR FASTNERS AND HOSES.......484
TORQUE LIST.......484
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.......485
MAINTENANCE SCHEDULE CHART.......486
INITIAL 250 HOURS SERVICE.......486
WHEN REQUIRED.......486
EVERY 50 HOURS SERVICE.......486
EVERY 100 HOURS SERVICE.......486
EVERY 250 HOURS SERVICE.......486
EVERY 500 HOURS SERVICE.......487
EVERY 1000 HOURS SERVICE.......487
EVERY 2000 HOURS SERVICE.......487
EVERY 4000 HOURS SERVICE.......487
EVERY 8000 HOURS SERVICE.......487
GENERAL MAINTENANCE AND INSPECTION.......488
INITIAL 250 HOURS SERVICE.......488
CHANGE TRANSMISSION OIL FILTER CARTRIDGE.......488
REPLACE HYDRAULIC TANK FILTER ELEMENT.......488
WHEN REQUIRED.......488
CLEANING THE MACHINE.......488
ENGINE AIR FILTER.......490
CLEANING THE COOLING SYSTEM.......493
TRANSMISSION OIL LEVEL.......495
AXLE OIL LEVEL.......496
CHECK AXLE VENT.......498
AIR CONDITIONER CONDENSER.......498
WINDOW WASHING FLUID LEVEL.......499
CLEANING RADIATOR FINS.......500
CHECKING ELECTRICAL INTAKE AIR HEATER.......501
REPLACE BOLT-ON CUTTING EDGE.......501
REPLACE BUCKET TEETH.......502
REPLACING SLOW-BLOW FUSE.......503
INSPECTION OF TIRES.......504
EVERY SPECIFIC HOURS SERVICE.......506
EVERY 50 HOURS SERVICE.......506
DRAIN SEDIMENT FROM FUEL TANK.......506
EVERY 100 HOURS SERVICE.......506
LUBRICATE THE REAR AXLE PIVOT PIN.......506
CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL.......506
CLEANING THE AIR CONDITIONER FRESH AIR FILTER ELEMENT.......507
EVERY 250 HOURS SERVICE.......508
CHECK BATTERY ELECTROLYTE LEVEL.......508
CHECK PARKING BRAKE.......510
ALTERNATOR BELT TENSION.......510
AIR CONDITIONER COMPRESSOR BELT TENSION.......510
WHEEL HUB NUTS.......511
AIR CONDITIONER RECIRCULATION FILTER.......511
LUBRICATING POINTS.......512
EVERY 500 HOURS SERVICE.......513
CHANGE THE ENGINE OIL, REPLACE THE ENGINE OIL FILTER CARTRIDGE.......513
REPLACING FUEL FILTER CARTRIDGE.......514
CLEANING THE FUEL STRAINER.......515
EVERY 1000 HOURS SERVICE.......517
CHANGE TRANSMISSION OIL AND FILTER CARTRIDGE, CLEAN STRAINER.......517
CLEAN THE TRANSMISSION CASE VENT.......518
LUBRICATING POINTS.......519
CHECKING PARTS OF TURBOCHARGER.......519
REPLACE CORROSION RESISTOR CARTRIDGE.......519
EVERY 2000 HOURS SERVICE.......520
CHANGE HYDRAULIC OIL, REPLACE HYDRAULIC OIL FILTER ELEMENT.......520
HYDRAULIC TANK VENT ELEMENT.......522
CHANGE THE AXLE OIL.......523
AIR CONDITIONER RECIRCULATION FILTER.......523
CLEAN PPC CIRCUIT STRAINER.......524
CLEAN THE ENGINE VENT ELEMENT.......524
CHECK ALTERNATOR, STARTER MOTOR.......525
CHECK ENGINE VALVE CLEARANCE.......525
CHECK TURBOCHARGER.......525
CHECK INJECTOR.......525
CHECK ACCUMULATOR GAS PRESSURE.......525
CHECK VIBRATION DAMPER.......525
CHECKING BRAKE DISC WEAR.......526
EVERY 4000 HOURS SERVICE.......527
LUBRICATING POINTS.......527
CHECK WATER PUMP.......528
CHECK AIR CONDITIONER COMPRESSOR.......528
REPLACE INJECTOR NOZZLE TIP.......528
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.......528
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.......528
EVERY 8000 HOURS SERVICE.......529
REPLACE HIGH-PRESSURE PIPING CLAMP.......529
REPLACE FUEL SPRAY PREVENTION CAP.......529
SPECIFICATIONS.......530
SPECIFICATIONS.......531
WA480-5L WITH BOLT-ON CUTTING EDGE.......531
MACHINE DIMENSIONS AND WEIGHTS.......532
TIRES.......532
WORK EQUIPMENT.......533
WEIGHT CHANGES.......534
MACHINE SYSTEMS SPECIFICATIONS.......535
ENGINE.......535
TRANSMISSION.......536
AXLES AND FINAL DRIVES.......536
BRAKES.......536
STEERING SYSTEM.......536
SERVICE REFILL CAPACITIES.......536
OPTIONS, ATTACHMENTS.......538
MONITOR WITH LOAD METER.......539
LOAD METER.......539
SWITCHES.......539
LOAD METER CANCEL SWITCH.......540
LOAD METER SUB TOTAL SWITCH.......540
LOAD METER FUNCTIONS.......541
LOAD METER ADDITION MODE.......541
LOAD METER REMAIN MODE.......542
SELECTION OF DISPLAY FOR TYPE OF LOAD.......542
METHOD OF CALIBRATION (ADJUSTING 0 POINT).......543
DELETING LOAD METER DISPLAY.......543
SPEED DISPLAY.......543
USING LOAD METER DISPLAY.......544
SETTING ADDITION MODE.......544
SETTING THE REMAIN MODE.......545
TOTAL LOAD DATA DISPLAY.......547
STOPPING THE CALCULATION.......548
PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY.......549
PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED.......550
SUBTRACTION FUNCTION.......552
SETTING THE TIME ON THE CLOCK.......555
PRINTER OUTPUT.......557
PRINTOUT MODE.......557
SELECTING THE PRINTOUT MODE.......558
TORQUE CONVERTER LOCK-UP.......559
GENERAL LOCATIONS.......559
TORQUE CONVERTER LOCK-UP SWITCH.......559
TORQUE CONVERTER LOCK-UP PILOT LAMP.......560
METHOD OF OPERATION.......560
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED.......561
TRAVEL SPEED WARNING FUNCTION.......561
TRAVEL SPEED LIMIT FUNCTION.......561
WASTE HANDLER ENGINE COOLING FAN CONTROL SYSTEM.......562
FAN SYSTEM OPERATION.......562
MODE SELECTOR SWITCH.......563
FORWARD/REVERSE TIMER.......563
REVERSE/FORWARD INDICATOR LAMPS.......563
FORWARD SETTING KNOB.......564
REVERSE SETTING KNOB.......564
FORWARD TIME UNIT SELECTOR SWITCH.......565
SCALE FIGURE SELECTOR SWITCH.......565
DIRECTION SELECTOR SWITCH.......566
REVERSE PILOT LAMP.......566
CONTROL BOX.......566
CLEANING RADIATOR AND COOLER FINS.......567
HANDLING JOYSTICK STEERING SYSTEM.......569
EXPLANATION OF COMPONENTS.......569
SHIFT UP, SHIFT DOWN SWITCHES.......569
FNR SWITCH.......570
JOYSTICK STEERING LEVER.......570
JOYSTICK ON/OFF SWITCH.......570
HI/LOW SELECTOR SWITCH.......570
HORN SWITCH.......571
CONSOLE LOCK LEVER.......571
HEIGHT ADJUSTMENT LOCK LEVER.......571
ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER.......571
STRUCTURE AND FUNCTION OF JOYSTICK STEERING.......572
JOYSTICK AND STEERING WHEEL OPERATION.......573
GETTING IN OR OUT OF THE OPERATOR'S CAB.......573
JOYSTICK CONSOLE ADJUSTMENT.......574
JOYSTICK OPERATION.......574
EPC WORK EQUIPMENT LEVER.......577
SWITCHES.......577
AUTO-GREASING SYSTEM.......578
OPERATING AUTO-GREASING SYSTEM.......578
REMAINING NUMBER OF TIMES OF GREASE.......579
OPERATION AS DESIRED.......579
PILOT LAMP DISPLAY ON MACHINE MONITOR.......580
SETTING GREASE TIME.......580
SETTING GREASING TIME IN COLD AREAS.......580
METHOD OF SETTING.......581
CHECK THE AMOUNT OF GREASE.......582
REPLACEMENT OF GREASE CARTRIDGE.......582
PRECAUTIONS WHEN HANDLING AUTO GREASING SYSTEM.......584
TROUBLESHOOTING.......584
CEBM009601 - Wheel Loader GALEO WA450-5L, WA480-5L Shop Manual.......588
COVER.......588
CONTENTS.......589
FOREWORD.......600
SAFETY.......600
SAFETY NOTICE.......600
IMPORTANT SAFETY NOTICE.......600
GENERAL PRECAUTIONS.......600
PREPARATIONS FOR WORK.......600
PRECAUTIONS DURING WORK.......600
GENERAL.......602
HOW TO READ THE SHOP MANUAL.......603
VOLUMES.......603
DISTRIBUTION AND UPDATING.......603
FILING METHOD.......603
REVISED EDITION MARK.......603
REVISIONS.......603
SYMBOLS.......603
HOISTING INSTRUCTIONS.......604
HOISTING.......604
WIRE ROPES.......604
COATING MATERIALS.......605
STANDARD TIGHTENING TORQUE.......607
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS.......607
TIGHTENING TORQUE OF HOSE NUTS.......608
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS.......608
TIGHTENING TORQUE FOR FLARED NUTS.......608
ELECTRIC WIRE CODE.......609
CLASSIFICATION BY THICKNESS.......609
CLASSIFICATION BY COLOR AND CODE.......609
CONVERSION TABLES.......610
METHOD OF USING THE CONVERSION TABLE.......610
01 GENERAL.......616
SPECIFICATIONS.......617
WEIGHT TABLE.......622
FUEL, COOLANT AND LUBRICANTS.......624
10 STRUCTURE AND FUNCTION.......626
RADIATOR, OIL COOLER.......630
ENGINE MOUNT, TRANSMISSION MOUNT.......631
POWER TRAIN.......632
POWER TRAIN SYSTEM DIAGRAM.......633
Without torque converter lock-up clutch.......633
With torque converter lock-up clutch (optional).......634
DRIVE SHAFT (PROPELLER SHAFT).......636
TORQUE CONVERTER, TRANSMISSION PIPING.......637
TORQUE CONVERTER.......638
WITHOUT LOCK-UP CLUTCH.......638
Path of power transmission.......641
With lock-up clutch (optional).......642
Path of power transmission.......646
TRANSMISSION.......648
F-R clutch (without lock-up clutch).......655
F-R clutch (with optional lock-up clutch).......656
1st-4th CLUTCH.......657
2nd-3rd CLUTCH.......658
Operation of clutch.......659
FORWARD 1ST.......660
FORWARD 2ND.......661
FORWARD 3RD.......662
FORWARD 4TH.......663
REVERSE 1ST.......664
TRANSMISSION CONTROL VALVE.......665
Without lock-up clutch.......665
With lock-up clutch.......667
ECMV actuation table (with lock-up clutch).......668
ECMV (Electronic Control Modulation Valve).......669
ECMV for speed clutch.......670
ECMV for lock-up clutch.......673
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE.......675
FLOW VALVE.......677
AXLE.......678
FRONT AXLE.......678
REAR AXLE.......680
Differential.......682
Anti-slip Differential.......682
Operation of anti-slip differential.......686
When traveling in a straight line.......686
FRONT DIFFERENTIAL.......688
REAR DIFFERENTIAL.......690
Outline.......692
FINAL DRIVE.......693
AXLE MOUNTING, CENTER HINGE PIN.......698
STEERING PIPING.......702
STEERING COLUMN, ORBIT-ROLL.......703
STEERING VALVE.......704
OVERLOAD RELIEF VALVE.......706
Function.......706
Operation.......706
STEERING RELIEF VALVE.......708
Function.......708
Operation of steering relief valve.......709
Operation of demand valve.......710
Operation of steering valve.......713
ORBIT-ROLL VALVE.......716
CONNECTION BETWEEN HAND PUMP AND SLEEVE.......718
STOP VALVE.......720
STEERING PUMP, SWITCH PUMP.......722
Outline.......722
EMERGENCY STEERING PUMP (optional).......724
Function.......724
EMERGENCY STEERING MOTOR (optional).......725
Function.......725
STEERING CYLINDER.......726
JOYSTICK STEERING LEVER (optional).......728
STEERING SWITCH VALVE (optional).......729
(FOR JOYSTICK STEERING LEVER).......729
BRAKE PIPING.......730
BRAKE VALVE.......732
BRAKE VALVE (LEFT).......732
BRAKE VALVE (RIGHT).......734
Operation.......736
CHARGE VALVE.......739
Operation.......741
ACCUMULATOR (FOR BRAKE).......743
Function.......743
Function.......744
SLACK ADJUSTER.......745
Outline.......746
Operation.......746
BRAKE.......747
FRONT.......747
Outline.......748
REAR.......749
Outline.......750
Outline.......751
PARKING BRAKE CONTROL.......752
Outline.......752
PARKING BRAKE.......753
Outline.......753
PARKING BRAKE SOLENOID VALVE.......755
Operation.......755
Operation.......756
PARKING BRAKE EMERGENCY RELEASE VALVE.......757
Outline.......757
HYDRAULIC PIPING.......758
Outline.......760
WORK EQUIPMENT CONTROL LEVER.......761
For PPC valve.......761
HYDRAULIC TANK.......762
Breather.......763
TORQUE CONVERTER CHARGING, WORK EQUIPMENT AND PPC PUMPS.......764
Outline.......764
PPC RELIEF VALVE.......766
Outline.......766
Operation.......767
TRAVEL DAMPER VALVE.......768
WORK EQUIPMENT CONTROL VALVE.......770
PPC VALVE.......790
COOLING FAN MOTOR.......796
Model: LMF28.......796
COOLING FAN MOTOR DRIVE PUMP.......801
Model: LPV30.......801
SERVO VALVE.......805
SAFETY VALVE.......807
WORK EQUIPMENT LINKAGE.......808
BUCKET.......810
BUCKET POSITIONER, LIFT ARM KICK-OUT.......811
Lift arm kick-out.......812
Operation of proximity switch.......813
WORK EQUIPMENT CYLINDER.......819
LIFT ARM CYLINDER.......819
BUCKET CYLINDER.......819
CAB.......821
AIR CONDITIONER.......822
AIR CONDITIONER PIPING.......822
MACHINE MONITORING SYSTEM.......823
Outline.......823
Individual circuit diagrams of the machine monitor.......825
Starting and lighting functions.......825
Load meter.......825
Sensing functions.......826
Power supply and network.......827
MACHINE MONITOR.......830
Load meter specifications (optional).......831
TABLE OF MONITOR INDICATION ITEMS.......832
SETTING OF THE MACHINE MONITOR.......837
Service mode functions.......841
Items Related to the Fault History of Electric System.......845
Items Related to the Fault History of Machine System.......847
Items Related to Maintenance Monitor.......849
Engine Cylinders Cut-Out Function.......852
Real-time Monitoring Function.......854
Real-time Monitoring Items.......857
Machine setting.......868
Setting necessary for option mounting.......871
Optional device setting for machine monitor.......872
TRANSMISSION CONTROL SYSTEM.......888
System Diagram.......888
Control Function.......889
Electric Circuit Diagram (STD).......908
Electric Circuit Diagram (optional).......910
TRANSMISSION CONTROLLER.......912
ELECTRIC TRANSMISSION CONTROL.......914
Functions.......915
COMBINATION SWITCH.......916
Overview.......916
Functions.......916
Operation.......917
KICK DOWN HOLD SWITCH.......918
Functions.......918
Joystick steering control.......919
ENGINE STARTING CIRCUIT.......922
Function.......922
Operation.......923
ENGINE STOP CIRCUIT.......924
Operation.......924
PARKING BRAKE CIRCUIT.......925
Operation.......925
TURN SIGNAL, HAZARD LAMP CIRCUIT.......929
Operation.......929
BACKUP LAMP, STOP LAMP CIRCUIT.......931
Operation.......931
SMALL LAMP, HEAD LAMP CIRCUIT.......933
Operation.......933
WORKING LAMP CIRCUIT.......934
Operation.......934
HORN CIRCUIT.......935
Operation.......935
WINDSHIELD WIPER/WINDOW WASHER CIRCUIT.......936
Operation.......936
SENSORS.......938
ENGINE SPEED SENSOR.......938
Speed sensor.......938
ENGINE OIL PRESSURE SENSOR.......939
ENGINE OIL LEVEL SENSOR.......939
ENGINE WATER TEMPERATURE SENSOR.......940
TORQUE CONVERTER OIL TEMPERATURE SENSOR.......940
HYDRAULIC OIL TEMPERATURE SENSOR.......940
TRANSMISSION OIL TEMPERATURE SENSOR.......940
BRAKE OIL TEMPERATURE SENSOR.......940
TRANSMISSION CUT-OFF PRESSURE SENSOR.......941
RADIATOR WATER LEVEL SENSOR.......942
FUEL LEVEL SENSOR.......943
LIFT ARM ANGLE SENSOR (optional Load Meter).......944
AIR CLEANER CLOGGING SENSOR.......945
PRESSURE SENSOR FOR LOAD METER (optional).......946
BATTERY LIQUID SENSOR (optional).......947
RELAY.......948
20 TESTING, ADJUSTING AND TROUBLESHOOTING.......950
STANDARD VALUE TABLE FOR ENGINE.......951
STANDARD VALUE TABLE FOR CHASSIS.......952
ENGINE COMPONENTS.......959
MEASURING EXHAUST SMOKE.......959
MEASURING EXHAUST TEMPERATURE.......959
ADJUSTING VALVE CLEARANCE.......959
MEASURING COMPRESSION PRESSURE.......959
MEASURING CRANCASE PRESSURE.......959
MEASURING ENGINE OIL PRESSURE.......959
MEASURING BOOST PRESSURE.......959
MEASURING FUEL PRESSURE.......959
ADJUSTING ENGINE SPEED SENSOR.......959
BLEEDING AIR FROM FUEL SYSTEM.......959
MEASURING ENGINE SPEED.......960
ADJUSTING ACCELERATOR PEDAL.......962
POTENTIOMETER.......962
MICROSWITCH.......964
ADJUSTING TRANSMISSION SPEED SENSOR.......965
POWER TRAIN OIL PRESSURE.......966
FLUSHING.......970
TORQUE CONVERTER, TRANSMISSION AND HYDRAULIC CIRCUIT.......970
TRANSMISSION VALVE FAILS.......971
MOVING MACHINE.......971
STEERING CONTROL.......973
STEERING OIL PRESSURE.......974
BRAKE SYSTEM.......976
MEASURING BRAKE OIL PRESSURE.......976
TESTING WEAR OF WHEEL BRAKE DISC.......978
BLEEDING AIR FROM BRAKE CIRCUIT.......979
TESTING WEAR OF PARKING BRAKE DISC.......980
MANUAL RELEASE METHOD FOR PARKING BRAKE.......981
ACCUMULATOR CHARGE PRESSURE.......982
PPC OIL PRESSURE.......984
WORK EQUIPMENT HYDRAULIC PRESSURE.......987
BUCKET POSITIONER.......989
LIFT ARM KICK-OUT.......990
PROXIMITY SWITCH ACTUATION.......991
ADJUSTING MACHINE MONITOR.......992
LOAD METER.......995
BLEEDING AIR.......996
RELEASING REMAINING PRESSURE.......997
IN HYDRAULIC CIRCUIT.......997
IN TRAVEL DAMPER CIRCUIT.......998
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT.......999
TROUBLESHOOTING GENERAL.......1000
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......1001
SEQUENCE OF EVENTS IN TROUBLESHOOTING.......738
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.......738
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT.......738
HANDLING CONTROL BOX.......1009
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.......741
CHECKS BEFORE TROUBLESHOOTING.......743
EQUIPMENT FOR TROUBLESHOOTING ELECTRICAL SYSTEM.......1013
TROUBLESHOOTING MACHINE MONITOR.......1014
SPECIAL FUNCTIONS OF MACHINE MONITOR.......1015
FLOW OF MODES AND FUNCTIONS.......1016
FAILURE CODE TABLE.......1024
MONITORING CODE TABLE.......1038
USING TROUBLESHOOTING CHARTS.......1050
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.......1054
TROUBLESHOOTING OF ENGINE CONTROL SYSTEM (ENG MODE).......1076
CONNECTOR TYPES AND INSTALLATION LOCATIONS.......1077
CONNECTOR ARRANGEMENT LOCATIONS.......1085
ENGINE CONTROL SYSTEM DIAGRAM.......1091
ERROR CODE [A000N1].......1093
ENGINE OVERRUNS (N1).......1093
ERROR CODE [AD00L2].......1094
COMMON RAIL HIGHER THAN SET VALUE.......1094
ERROR CODE [AD10L3].......1095
FUEL SUPPLY PUMP CANNOT BE CONTROLLED.......1095
ERROR CODE [AD00MA].......1098
FUNCTION OF COMMON RAIL IS DEFECTIVE.......1098
ERROR CODE [AD10MA].......1099
FUEL SUPPLY PUMP IS DEFECTIVE.......1099
ERROR CODE [AD10MB].......1100
FUEL SUPPLY PUMP FLOW LOWERED.......1100
ERROR CODE [AD11KA].......1101
OPEN IN FUEL SUPPLY PUMP PVC1 SYSTEM.......1101
ERROR CODE [AD11KB].......1103
SHORT CIRCUIT IN FUEL SUPPLY PUMP PCV1.......1103
ERROR CODE [AD51KA].......1105
OPEN IN FUEL SUPPLY PUMP PCV2.......1105
ERROR CODE [AD51KB].......1107
SHORT CIRCUIT IN FUEL SUPPLY PUMP PVC2.......1107
ERROR CODE [ADA1KA].......1109
OPEN IN NO. 1 INJECTOR SOLENOID VALVE.......1109
ERROR CODE [ADAZKB].......1111
SHORT CIRCUIT IN NO. 1, 2, 3 INJECTOR SOLENOID VALVE.......1111
ERROR CODE [ADB1KA].......1113
OPEN IN NO. 2 INJECTOR SOLENOID VALVE.......1113
ERROR CODE [ADC1KA].......1114
OPEN IN NO. 3 INJECTOR SOLENOID VALVE.......1114
ERROR CODE [ADD1KA].......1115
OPEN IN NO. 4 INJECTOR SOLENOID VALVE.......1115
ERROR CODE [ADDZKB].......1117
SHORT CIRCUIT IN NO. 4, 5, 6 INJECTOR SOLENOID VALVE.......1117
ERROR CODE [ADE1KA].......1119
OPEN IN NO. 5 INJECTOR SOLENOID VALVE.......1119
ERROR CODE [ADF1KA].......1120
OPEN IN NO. 6 INJECTOR SOLENOID VALVE.......1120
ERROR CODE [D182KZ].......1121
OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL.......1121
ERROR CODE [D1D0KB].......1123
SHORT CIRCUIT IN VOLTAGE LOAD POWER SUPPLY.......1123
ERROR CODE [DB20KT].......1125
CONTROLLER POWER SUPPLY (NSW) VOLTAGE IS LOW.......1125
ERROR CODE [AB20KT].......1127
TROUBLE IN DRIVE CIRCUIT IN CONTROLLER.......1127
ERROR CODE [DB22KK].......1129
ENGINE CONTROLLER LOAD POWER SUPPLY (SW) 1.......1129
ERROR CODE [DB29KQ].......1131
NONCONFORMANCE OF MODEL SELECTION SIGNALS IN ENGINE CONTROLLER CONNECTING WIRING HARNESS.......1131
ERROR CODE [DB2AMA].......1133
FUNCTION OF Q ADJUSTMENT SWITCH OF ENGINE CONTROLLER IS DEFECTIVE.......1133
ERROR CODE [DD11KB].......1135
TROUBLE IN INPUT OF STARTING SWITCH C (IGN C).......1135
ERROR CODE [DGE3L6].......1137
TROUBLE IN WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM.......1137
ERROR CODE [DGE4KX].......1138
TROUBLE IN FUEL TEMPERATURE SENSOR SYSTEM.......1138
ERROR CODE [DH30KX].......1139
TROUBLE IN BOOST PRESSURE SENSOR SYSTEM.......1139
ERROR CODE [DH40KX].......1141
TROUBLE IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM.......1141
ERROR CODE [DK10KX].......1143
TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM.......1143
ERROR CODE [DLE3LC].......1145
TROUBLE IN ENGINE NE SPEED SENSOR SYSTEM.......1145
ERROR CODE [DLH1LC].......1146
TROUBLE IN ENGINE G SPEED SENSOR SYSTEM.......1146
ERROR CODE [ENG-1].......1147
ENGINE DOES NOT START.......1147
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE).......1152
CONNECTOR TYPES AND INSTALLATION POSITIONS.......1156
CONNECTOR LAYOUT DRAWING.......1164
TRANSMISSION RELATED SYSTEM DIAGRAM.......1170
ERROR CODE [1500L1].......1173
DOUBLE ENGAGEMENT DETECTED.......1173
ERROR CODE [15SAL1].......1174
F ECMV FILL SWITCH SYSTEM SHORT CIRCUITED.......1174
ERROR CODE [15SALH].......1175
F ECMV FILL SWITCH SYSTEM DISCONNECTED.......1175
ERROR CODE [15SBL1].......1176
R ECMV FILL SWITCH SYSTEM SHORT CIRCUITED.......1176
ERROR CODE [15SBLH].......1177
R ECMV FILL SWITCH SYSTEM DISCONNECTED.......1177
ERROR CODE [15SEL1].......1178
1ST ECMV FILL SWITCH SYSTEM SHORT CIRCUITED.......1178
ERROR CODE [15SELH].......1179
1ST ECMV FILL SWITCH SYSTEM DISCONNECTED.......1179
ERROR CODE [15SFL1].......1180
2ND ECMV FILL SWITCH SYSTEM SHORT CIRCUITED.......1180
ERROR CODE [15SFLH].......1181
2ND ECMV FILL SWITCH SYSTEM DISCONNECTED.......1181
ERROR CODE [15SGL1].......1182
3RD ECMV FILL SWITCH SYSTEM SHORT CIRCUITED.......1182
ERROR CODE [15SGLH].......1183
3RD ECMV FILL SWITCH SYSTEM DISCONNECTED.......1183
ERROR CODE [15SHL1].......1184
4TH ECMV FILL SWITCH SYSTEM SHORT CIRCUITED.......1184
ERROR CODE [15SHLH].......1185
4TH ECMV FILL SWITCH SYSTEM DISCONNECTED.......1185
ERROR CODE [15SJL1].......1186
LOCKUP ECMV FILL SWITCH SYSTEM SHORT CIRCUITED.......1186
ERROR CODE [15SJLH].......1187
LOCKUP ECMV FILL SWITCH SYSTEM DISCONNECTED.......1187
ERROR CODE [989F00].......1188
TRANSMISSION PROTECTION CAUTION.......1188
ERROR CODE [989G00].......1189
FNR LEVER PRIORITY CAUTION.......1189
ERROR CODE [B@C7NS].......1190
REAR BRAKE COOLING OIL OVERHEAT.......1190
ERROR CODE [D150KA].......1191
EMERGENCY STEERING RELAY OUTPUT SYSTEM DISCONNECTED.......1191
ERROR CODE [D150KB].......1192
EMERGENCY STEERING RELAY OUTPUT SYSTEM GROUNDED.......1192
ERROR CODE [D160KA].......1193
EMERGENCY STEERING RELAY OUTPUT SYSTEM GROUNDED.......1193
ERROR CODE [D160KB].......1194
BACKUP LAMP RELAY OUTPUT SYSTEM GROUNDED.......1194
ERROR CODE [D191KA].......1196
NEUTRAL SAFETY RELAY OUTPUT SYSTEM DISCONNECTED.......1196
ERROR CODE [D191KB].......1198
NEUTRAL SAFETY RELAY OUTPUT SYSTEM GROUNDED.......1198
ERROR CODE [D192KA].......1200
BOOM DAMPER RELAY OUTPUT SYSTEM DISCONNECTED.......1200
ERROR CODE [D192KB].......1201
LIFT ARM DAMPER RELAY OUTPUT SYSTEM GROUNDED.......1201
ERROR CODE [DAQ0KK].......1202
CONTROLLER POWER SUPPLY VOLTAGE LOWERED.......1202
ERROR CODE [DAQ2KK].......1203
DEFECTIVE SOLENOID POWER SUPPLY SYSTEM.......1203
ERROR CODE [DAQ9KQ].......1204
MODEL SELECTION SIGNAL MISMATCH.......1204
ERROR CODE [DDK3KA].......1206
RIGHT FNR SWITCH SIGNAL NOT INPUT.......1206
ERROR CODE [DDK3KB].......1208
MULTIPLE RIGHT FNR SWITCH SIGNAL INPUT.......1208
ERROR CODE [DDK6KA].......1210
FORWARD-REVERSE LEVER SIGNAL NOT INPUT.......1210
ERROR CODE [DDK6KB].......1212
MULTIPLE FORWARD-REVERSE LEVER SIGNAL INPUT.......1212
ERROR CODE [DDS5KA].......1214
STEERING PRESSURE SWITCH DISCONNECTED.......1214
ERROR CODE [DDS5KB].......1215
STEERING PRESSURE SWITCH GROUNDED.......1215
ERROR CODE [DDT0L4].......1216
MANUAL/AUTO-SHIFT SELECTOR SWITCH SELECTION FAILURE.......1216
ERROR CODE [DDT4LD].......1218
GROUND FAULT OF TRANSMISSION CUT-OFF SETTING SWITCH.......1218
ERROR CODE [DDW9LD].......1219
GROUND FAULT OF KICKDOWN SWITCH SYSTEM.......1219
ERROR CODE [DDWLLD].......1220
GROUND FAULT OF HOLD SWITCH SYSTEM.......1220
ERROR CODE [DF10KA].......1222
NO INPUT OF GEAR SHIFT LEVER SIGNAL.......1222
ERROR CODE [DF10KB].......1224
INPUT OF MULTIPLE GEAR SHIFT LEVER SIGNALS NO INPUT OF GEAR SHIFT LEVER SIGNAL.......1224
ERROR CODE [DGF1KX].......1226
TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM FAILURE.......1226
ERROR CODE [DGR2KA].......1227
REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM DISCONNECTION.......1227
ERROR CODE [DGR2KB].......1228
GROUND FAULT OF REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM DISCONNECTION.......1228
ERROR CODE [DHT1KX].......1229
TRANSMISSION CUT-OFF (LEFT BRAKE PRESSURE SENSOR) SIGNAL DISCONTINUITY.......1229
ERROR CODE [DLE2KA].......1230
ENGINE REVOLUTION SENSOR SYSTEM DISCONTINUITY.......1230
ERROR CODE [DLE2LC].......1231
eNGINE REVOLUTION SENSOR FAILURE.......1231
ERROR CODE [DLT3KA].......1232
SPEED SENSOR SYSTEM DISCONTINUITY.......1232
ERROR CODE [DT20KB].......1233
GROUND FAULT OF BUILT-IN INDICATOR LAMP SYSTEM OF TRANSMISSION CUT-OFF SWITCH.......1233
ERROR CODE [DW7BKA].......1234
FAN REVERSE SOLENOID SYSTEM DISCONTINUITY.......1234
ERROR CODE [DW7BKB].......1235
FAN REVERSE SOLENOID SYSTEM SHORT CIRCUITING.......1235
ERROR CODE [DW7CKA].......1236
SWITCH PUMP CUT-OFF RELAY DISCONTINUITY.......1236
ERROR CODE [DW7CKB].......1237
SWITCH PUMP CUT-OFF RELAY GROUND FAULT.......1237
ERROR CODE [DX16KA].......1238
FAN PUMP EPC SOLENOID SYSTEM DISCONTINUITY.......1238
ERROR CODE [DX16KB].......1239
FAN PUMP EPC SOLENOID SYSTEM GROUND FAULT.......1239
ERROR CODE [DXH1KA].......1240
LOCK-UP CLUTCH ECMV SOLENOID SYSTEM DISCONTINUITY.......1240
ERROR CODE [DXH1KB].......1241
LOCK-UP CLUTCH ECMV SOLENOID SYSTEM SHORT-CIRCUITING.......1241
ERROR CODE [DXH4KA].......1242
1ST ECMV SOLENOID SYSTEM DISCONTINUITY.......1242
ERROR CODE [DXH4KB].......1243
1ST ECMV SOLENOID SYSTEM SHORT CIRCUITING.......1243
ERROR CODE [DXH5KA].......1244
2ND ECMV SOLENOID SYSTEM DISCONTINUITY.......1244
ERROR CODE [DXH5KB].......1245
2ND ECMV SOLENOID SYSTEM SHORT CIRCUITING.......1245
ERROR CODE [DXH6KA].......1246
3RD ECMV SOLENOID SYSTEM DISCONTINUITY.......1246
ERROR CODE [DXH6KB].......1247
3RD ECMV SOLENOID SYSTEM SHORT CIRCUITING.......1247
ERROR CODE [DXH7KA].......1248
R ECMV SOLENOID SYSTEM DISCONTINUITY.......1248
ERROR CODE [DXH7KB].......1249
3RD ECMV SOLENOID SYSTEM GROUND FAULT.......1249
ERROR CODE [DXH8KA].......1250
F ECMV SOLENOID SYSTEM DISCONTINUITY.......1250
ERROR CODE [DXH8KB].......1251
F ECMV SOLENOID SYSTEM GROUND FAULT.......1251
ERROR CODE [DXHHKA].......1252
4TH ECMV SOLENOID SYSTEM DISCONTINUITY.......1252
ERROR CODE [DXHHKB].......1253
4TH ECMV SOLENOID SYSTEM SHORT CIRCUITING.......1253
ERROR CODE [DY30MA].......1254
MOTOR DRIVEN EMERGENCY STEERING PUMP ERROR (MALFUNCTION IN MANUAL MODE).......1254
ERROR CODE [DY30MC].......1256
MOTOR DRIVEN EMERGENCY STEERING PUMP ERROR (MALFUNCTION IN MANUAL MODE).......1256
ACTION CODE [TM-1].......1258
DISCONTINUITY OR SHORT CIRCUITING OF KICKDOWN SWITCH SYSTEM.......1258
ACTION CODE [TM-2].......1259
HOLD SWITCH SYSTEM DISCONTINUITY OR SHORT CIRCUITING (NO HOLD CONTROL PERFORMED BY PRESSING HOLD .........1259
ACTION CODE [TM-3].......1260
TORQUE CONVERTER LOCK-UP SWITCH SYSTEM FAILURE (NO LOCK-UP PERFORMED OR NO LOCK-UP CANCELLATION P.........1260
ACTION CODE [TM-4].......1262
NEUTRALIZER SIGNAL (PARKING BRAKE SWITCH SIGNAL) SYSTEM FAILURE.......1262
ACTION CODE [TM-5].......1264
EMERGENCY STEERING SWITCH (MOTOR DRIVEN EMERGENCY STEERING OPERATION SWITCH) SIGNAL SYSTEM FAILURE.......1264
ACTION CODE [TM-6].......1266
TRANSMISSION CUT-OFF SWITCH SYSTEM DISCONTINUITY OR GROUND FAULT.......1266
ACTION CODE [TM-7].......1267
TRANSMISSION CUT-OFF SETTING SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING.......1267
ACTION CODE [TM-8].......1269
TRANSMISSION CUT-OFF (LEFT BRAKE SENSOR) SIGNAL SHORT CIRCUITING.......1269
ACTION CODE [TM-9].......1271
JOYSTICK SHIFT UP/SHIFT DOWN SIWTCH SYSTEM FAILURE (DISCONTINUITY OR GROUND FAULT).......1271
ACTION CODE [TM-10-A].......1273
FNR SWITCH MODE CHANGE OVER SWITCH SYSTEM FAILURE.......1273
ACTION CODE [TM-10-B].......1275
STARTING SWITCH "C" (IGN C) SIGNAL SYSTEM FAILURE.......1275
ACTION CODE [TM-11].......1277
JOYSTICK ON/OFF CHANGE OVER SWITCH SYSTEM FAILURE.......1277
ACTION CODE [TM-12].......1279
ENGINE POWER MODE SWITCH DISCONTINUITY OR GROUND FAULT.......1279
ACTION CODE [TM-13].......1280
TRAVEL DAMPER ON/OFF SWITCH DISCONTINUITY OR GROUND FAULT.......1280
ACTION CODE [TM-14].......1281
HYDRAULIC FAN REVERSE SWITCH SIGNAL SYSTEM SHORT CIRCUITING OR DISCONTINUITY.......1281
ACTION CODE [TM-15].......1282
MOTOR DRIVEN EMERGENCY STEERING RELAY OUTPUT SYSTEM HOT SHORT CIRCUITING.......1282
ACTION CODE [TM-16].......1283
TRAVEL DAMPER RELAY OUTPUT SYSTEM SHORT CIRCUITING.......1283
ACTION CODE [TM-17].......1284
SWITCH PUMP CUT-OFF RELAY OUTPUT SYSTEM SHORT CIRCUITING.......1284
ACTION CODE [TM-18].......1285
BACK LAMP RELAY OUTPUT SYSTEM HOT SHORT CIRCUITING.......1285
ACTION CODE [TM-19].......1286
NEUTRAL OUTPUT SYSTEM SHORT CIRCUITING.......1286
ACTION CODE [TM-20].......1287
FECMV SOLENOID SYSTEM SHORT CIRCUITING.......1287
ACTION CODE [TM-21].......1288
RECMV SOLENOID SYSTEM sHORT CIRCUITING.......1288
ACTION CODE [TM-22].......1289
1ST ECMV SOLENOID SYSTEM SHORT CIRCUITING.......1289
ACTION CODE [TM-23].......1290
2ND ECMV SOLENOID SYSTEM HOT SHORT CIRCUITING.......1290
ACTION CODE [TM-24].......1291
3RD ECMV SOLENOID SYSTEM HOT SHORT CIRCUITING.......1291
ACTION CODE [TM-25].......1292
4TH ECMV SOLENOID SYSTEM HOT SHORT CIRCUITING.......1292
ACTION CODE [TM-26].......1293
LOCK-UP ECMV SOLENOID SYSTEM HOT SHORT CIRCUITING.......1293
ACTION CODE [TM-27].......1294
FAN PUMP EPC SOLENOID SYSTEM HOT SHORT CIRCUITING.......1294
ACTION CODE [TM-28].......1295
FAN REVERSE SOLENOID SYSTEM SHORT CIRCUITING.......1295
ACTION CODE [TM-29].......1296
SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM FAILURE.......1296
TROUBLESHOOTING MACHINE MONITOR PANEL SYSTEM (MON MODE).......1297
CONNECTOR TYPES AND INSTALLATION LOCATIONS.......1300
CONNECTOR LAYOUT DRAWING.......1307
MONITOR SYSTEM DIAGRAM.......1313
ERROR CODE [2F00KM].......1317
DRAGGING PARKING BRAKE.......1317
ERROR CODE [2G42ZG].......1319
ACCUMULATOR OIL PRESSURE (FRONT CIRCUIT) LOW.......1319
ERROR CODE [2G43ZG].......1321
ACCUMULATOR OIL PRESSURE (REAR BRAKE CIRCUIT) LOW.......1321
ERROR CODE [AA1ANX].......1323
AIR CLEANER 1 CLOGGED.......1323
ERROR CODE [AB00L6].......1325
DEFECTIVE BATTERY CHARGING CIRCUIT (ALTERNATOR TERMINAL R SIGNAL DETECTED WHEN ENGINE STOPPED).......1325
ERROR CODE [AB00MA].......1327
DEFECTIVE BATTERY CHARGING CIRCUIT (NO ALTERNATOR TERMINAL R SIGNAL DETECTED, DETECTION FAILURE).......1327
ERROR CODE [B@BAZG].......1329
ENGINE OIL PRESSURE LOW.......1329
ERROR CODE [B@BAZK].......1330
ENGINE OIL LEVEL LOW.......1330
ERROR CODE [B@BCNS].......1331
ENGINE WATER TEMPERATURE OVERHEATING.......1331
ERROR CODE [B@BCZK].......1332
ALARM INDICATING LOW COOLANT LEVEL.......1332
ERROR CODE [B@HANS].......1333
HYDRAULIC OIL TEMPERATURE OVERHEATING.......1333
ERROR CODE [B@CENS].......1334
TORQUE CONVERTER OIL TEMPERATURE OVERHEATING.......1334
ERROR CODE [D5ZHL6].......1335
STARTING SWITCH C (IGN "C") INPUT FAILURE.......1335
ERROR CODE [DAF3KK].......1337
SW POWER SUPPLY (FOR OPERATION) = ON AND NSW POWER SUPPLY (FOR MEMORY) = OFF.......1337
ERROR CODE [DAF5KP].......1339
5-V POWER SUPPLY OUTPUT FAILURE.......1339
ERROR CODE [DAF6KP].......1341
24-V POWER SUPPLY OUTPUT FAILURE.......1341
ERROR CODE [DAFBKM].......1343
WRONG INFORMATION ON MODEL SELECTION.......1343
ERROR CODE [DAFSKQ].......1344
WRONG INFORMATION ON METER DISPLAY SELECTION.......1344
ERROR CODE [DAQSKR].......1345
S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND TRANSMISSION CONTROLLER) SELECTION.......1345
ERROR CODE [DBQSKR].......1347
S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND ENGINE CONTROLLER).......1347
ERROR CODE [DB9SKR].......1349
S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER).......1349
ERROR CODE [DD15LD].......1351
MONITOR PANEL MODE SELECTOR SWITCH 1 (PANEL SW1) INPUT ERROR.......1351
ERROR CODE [DD16LD].......1352
MONITOR PANEL MODE SELECTOR SWITCH 1 (PANEL SW2) INPUT ERROR.......1352
ERROR CODE [DD17LD].......1353
MONITOR PANEL MODE SELECTOR SWITCH 2 (PANEL SW3) INPUT ERROR.......1353
ERROR CODE [DD18LD].......1354
MONITOR PANEL MODE SELECTOR SWITCH 2 (PANEL SW3) INPUT ERROR.......1354
ERROR CODE [DD1CLD].......1355
SUB-TOTAL SWITCH FAILURE.......1355
ERROR CODE [DGE2KX].......1356
ENGINE WATER TEMPERATURE SENSOR SYSTEM FAILURE.......1356
ERROR CODE [DDK6KM].......1357
CAUTION: FNR (FORWARD-REVERSE) LEVER SWITCH IS IN N (NEUTRAL).......1357
ERROR CODE [DDS5L6].......1358
DECREASED STEERING OIL PRESSURE.......1358
ERROR CODE [DDY0LD].......1359
CANCEL SWITCH FAILURE.......1359
ERROR CODE [DGH2KX].......1360
HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM FAILURE.......1360
ERROR CODE [DGT1KX].......1361
TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM FAILURE.......1361
ERROR CODE [DHE4L6].......1362
ENGINE OIL PRESSURE SENSOR SYSTEM FAILURE.......1362
ERROR CODE [DHPCKX].......1363
BOTTOM PRESSURE SENSOR FAILURE.......1363
ERROR CODE [DHPDKX].......1365
HEAD PRESSURE SENSOR FAILURE.......1365
ERROR CODE [DKA0KX].......1367
BOOM ANGLE SENSOR FAILURE.......1367
ERROR CODE [DV00KB].......1369
SHORT-CIRCUITED ALARM BUZZER OUTPUT SYSTEM.......1369
ERROR CODE [DY30ME].......1370
THE EMERGENCY STEERING REMAINS ACTUATED FOR MORE THAN ONE MINUTE.......1370
ACTION CODE [MON-1].......1374
THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT UP WHEN THE PARKING BRAKE SWITCH IS TURNED ON.......1374
ACTION CODE [MON-2].......1376
CIRCUIT DIAGNOSTIC PROCEDURES FOR ERROR CODE.......1376
ACTION CODE [MON-3].......1377
THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (REAR C.........1377
ACTION CODE [MON-4].......1378
THE AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT ON.......1378
ACTION CODE [MON-5].......1380
THE ENGINE HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON.......1380
ACTION CODE [MON-6].......1381
THE ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT ON.......1381
ACTION CODE [MON-7].......1382
THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON.......1382
ACTION CODE [MON-8].......1383
THE RADIATOR WATER VOLUME CAUTION LAMP DOES NOT LIGHT ON.......1383
ACTION CODE [MON-9].......1384
THE HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON.......1384
ACTION CODE [MON-10].......1385
THE TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON.......1385
ACTION CODE [MON-11].......1386
THE STEERING HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON.......1386
ACTION CODE [MON-12].......1387
INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW1).......1387
ACTION CODE [MON-13].......1388
INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW2).......1388
ACTION CODE [MON-14].......1389
INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW3).......1389
ACTION CODE [MON-15].......1390
INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW4).......1390
ACTION CODE [MON-16].......1391
DEFECTIVE SUBTOTAL SWITCH.......1391
ACTION CODE [MON-17].......1392
DEFECTIVE CANCEL SWITCH.......1392
ACTION CODE [MON-18].......1394
DEFECTIVE BOTTOM PRESSURE SENSOR (HOT SHORT FAULT).......1394
ACTION CODE [MON-19].......1396
DEFECTIVE HEAD SENSOR.......1396
ACTION CODE [MON-20].......1398
THE ALARM BUZZER DOES NOT SOUND OR STOP.......1398
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEM (H MODE).......1400
ACTION CODE: [H-1].......1402
THE MACHINE DOES NOT START.......1402
ACTION CODE: [H-2].......1404
THE LOCK-UP CLUTCH IS NOT RELEASED (THE ENGINE STOPS) (WHEN THE LOCK-UP CLUTCH IS PROVIDED).......1404
ACTION CODE: [H-3A].......1405
THE TRAVEL SPEED IS SLOW, THE THRUSTING FORCE IS WEAK, THE UPHILL TRAVELING POWER IS WEAK, AND TH.........1405
ACTION CODE: [H-3B].......1407
THE TORQUE CONVERTER LOCK-UP CLUTCH IS NOT LET IN (WHEN THE LOCK-UP CLUTCH IS PROVIDED).......1407
ACTION CODE: [H-4].......1408
SHOCKS ARE LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR.......1408
ACTION CODE: [H-5].......1410
TIME LAG IS LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR.......1410
ACTION CODE: [H-6].......1412
THE TORQUE CONVERTER OIL TEMPERATURE IS HIGH.......1412
ACTION CODE: [H-7].......1413
THE STEERING WHEEL DOES NOT TURN.......1413
ACTION CODE: [H-8].......1414
THE STEERING WHEEL IS HEAVY.......1414
ACTION CODE: [H-9].......1415
THE STEERING WHEEL FLUCTUATES OR IS STRONGLY SHOCKED.......1415
ACTION CODE: [H-10].......1415
THE STEERING WHEEL FLUCTUATES OR IS STRONGLY SHOCKED.......1415
ACTION CODE: [H-11].......1415
THE RIGHT AND LEFT SWING RADII ARE DIFFERENT.......1415
ACTION CODE: [H-12].......1416
THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL.......1416
ACTION CODE: [H-13].......1417
THE BRAKE IS NOT RELEASED OR IS DRAGING.......1417
ACTION CODE: [H-14].......1418
THE BRAKE IS NOT RELEASED OR DRAGING.......1418
ACTION CODE: [H-15].......1419
THE BOOM DOES NOT RISE.......1419
ACTION CODE: [H-16].......1420
THE BOOM MOVES SLOWLY OR THE BOOM RISING FORCE IS INSUFFICIENT.......1420
ACTION CODE: [H-17].......1421
WHEN RISING, THE BOOM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT.......1421
ACTION CODE: [H-18].......1421
THE BOOM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR).......1421
ACTION CODE: [H-19].......1421
HYDRAULIC DRIFTS OF THE BOOM OCCUR OFTEN.......1421
ACTION CODE: [H-20].......1422
THE BOOM WOBBLES DURING OPERATION.......1422
ACTION CODE: [H-21].......1422
WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "RAISE," THE BOOM FALLS TEMPORARILY.......1422
ACTION CODE: [H-22].......1423
THE BUCKET DOES NOT TILT BACK.......1423
ACTION CODE: [H-23].......1424
THE BUCKET MOVES SLOWLY OR THE TILTING BACK FORCE IS INSUFFICIENT.......1424
ACTION CODE: [H-24].......1425
THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILTING- BACK.......1425
ACTION CODE: [H-25].......1425
THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET.......1425
ACTION CODE: [H-26].......1425
HYDRAULIC DRIFT OF THE BUCKET OCCURS OFTEN.......1425
ACTION CODE: [H-27].......1426
THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO "HOLD").......1426
ACTION CODE: [H-28].......1426
WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "TILT," THE BUCKET FALLS TEMPORARILY.......1426
ACTION CODE: [H-29].......1427
THE CONTROL LEVERS OF BOOM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY.......1427
TROUBLESHOOTING OF CHASSIS ELECTRICAL SYSTEM (E MODE).......1429
CONNECTOR TYPES AND INSTALLATION POSITIONS.......1430
CONNECTOR LAYOUT DRAWING.......1438
ELECTRICAL SYSTEM DIAGRAM.......1444
ACTION CODE: [E-1].......1446
ALL OF THE BUCKET POSITIONER, BOOM KICK-OUT, AND FLOATING HOLDER DO NOT FUNCTION.......1446
ACTION CODE [E-2].......1448
THE BOOM KICK-OUT DOES NOT FUNCTION OR CANNOT BE RELEASED.......1448
ACTION CODE: [E-3].......1452
THE BUCKET LEVER DOES NOT FUNCTION OR CANNOT BE RELEASED.......1452
ACTION CODE: [E-4].......1456
THE BOOM FLOATING HOLDER DOES NOT FUNCTION OR CANNOT BE RELEASED.......1456
ACTION CODE: [E-5A].......1458
THE FRONT WIPER DOES NOT FUNCTION.......1458
ACTION CODE: [E-5B].......1462
THE REAR WIPER DOES NOT FUNCTION.......1462
ACTION CODE: [E-5C].......1463
THE SIDE WIPER DOES NOT FUNCTION.......1463
ACTION CODE: [E-6].......1464
THE WIND WASHER DOES NOT FUNCTION.......1464
ACTION CODE: [E-7A].......1467
THE HEADLAMP (LO BEAM) DOES NOT LIGHT.......1467
ACTION CODE: [E-7B].......1470
THE HEADLAMP (HI BEAM) DOES NOT FUNCTION.......1470
ACTION CODE: [E-7C].......1472
THE CLEARANCE LAMP DOES NOT LIGHT (SMALL LAMP).......1472
ACTION CODE: [E-7D].......1473
THE TURN SIGNAL DOES NOT BLINK.......1473
ACTION CODE: [E-8].......1476
THE HORN DOES NOT SOUND.......1476
90 OTHERS.......1478
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN.......1480
(WITHOUT TORQUE CONVERTER LOCKUP CLUTCH).......1480
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN.......1481
(WITH TORQUE CONVERTER LOCKUP CLUTCH).......1480
CEBM009605 - Wheel Loader GALEO WA450-5L, WA480-5L Shop Manual.......1485
COVER.......1485
CONTENTS.......1486
FOREWORD.......1499
SAFETY.......1499
SAFETY NOTICE.......1499
IMPORTANT SAFETY NOTICE.......1499
GENERAL PRECAUTIONS.......1499
PREPARATIONS FOR WORK.......1499
PRECAUTIONS DURING WORK.......1499
GENERAL.......1501
HOW TO READ THE SHOP MANUAL.......1502
VOLUMES.......1502
DISTRIBUTION AND UPDATING.......1502
FILING METHOD.......1502
REVISED EDITION MARK.......1502
REVISIONS.......1502
SYMBOLS.......1502
HOISTING INSTRUCTIONS.......1503
HOISTING.......1503
WIRE ROPES.......1503
PUSH PULL COUPLER.......1504
TYPE 1.......1504
TYPE 2.......1505
TYPE 3.......1506
COATING MATERIALS.......1507
STANDARD TIGHTENING TORQUE.......1509
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS.......1509
TIGHTENING TORQUE OF HOSE NUTS.......1510
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS.......1510
TIGHTENING TORQUE FOR FLARED NUTS.......1510
ELECTRIC WIRE CODE.......1511
CLASSIFICATION BY THICKNESS.......1511
CLASSIFICATION BY COLOR AND CODE.......1511
CONVERSION TABLES.......1512
METHOD OF USING THE CONVERSION TABLE.......1512
01 GENERAL.......1519
SPECIFICATIONS.......1520
WEIGHT TABLE.......1524
FUEL, COOLANT AND LUBRICANTS.......1525
10 STRUCTURE AND FUNCTION.......1527
RADIATOR AND OIL COOLER.......1535
SPECIFICATIONS.......1535
ENGINE AND TRANSMISSION MOUNT.......1536
POWER TRAIN.......1537
OUTLINE.......1537
POWER TRAIN SYSTEM DIAGRAM.......1538
WITHOUT TORQUE CONVERTER LOCK UP CLUTCH.......1538
WITH TORQUE CONVERTER LOCK UP CLUTCH.......1539
DRIVE SHAFT.......1541
DRIVE TRAIN PIPING.......1542
TORQUE CONVERTER.......1543
WITHOUT LOCK UP CLUTCH.......1543
SPECIFICATIONS.......1543
PATH OF POWER TRANSMISSION.......1545
WITH LOCK UP CLUTCH.......1546
SPECIFICATIONS.......1546
PATH OF POWER TRANSMISSION.......1550
TRANSMISSION.......1552
OUTLINE.......1557
CLUTCH AND REDUCTION GEAR RATIO TABLE.......1557
F & R CLUTCH WITHOUT LOCK UP CLUTCH.......1558
F & R CLUTCH WITH LOCK UP CLUTCH.......1559
1ST & 4TH CLUTCH.......1560
2ND & 3RD CLUTCH.......1561
OPERATION OF CLUTCH.......1562
CLUTCH ENGAGED.......1562
CLUTCH DISENGAGED.......1562
FORWARD 1ST.......1563
FORWARD 2ND.......1564
FORWARD 3RD.......1565
FORWARD 4TH.......1566
REVERSE 1ST.......1567
TRANSMISSION CONTROL VALVE.......1568
WITHOUT LOCK UP CLUTCH.......1568
ECMV ACTUATION TABLE.......1569
OUTLINE.......1569
WITH LOCK UP CLUTCH.......1570
ECMV ACTUATION TABLE.......1571
OUTLINE.......1571
ECMV - ELECTRONIC CONTROL MODULATION VALVE.......1572
ECMV FOR SPEED CLUTCH.......1573
ECMV FOR LOCK UP CLUTCH.......1576
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE.......1578
OUTLINE.......1579
OPERATION.......1579
FLOW VALVE.......1580
OPERATION.......1580
AXLES.......1581
FRONT AXLE.......1581
WA450-5L.......1581
WA480-5L.......1582
REAR AXLE.......1583
WA450-5L.......1583
WA480-5L.......1584
AXLE MOUNTING.......1585
FRONT AXLE.......1585
REAR AXLE.......1586
DIFFERENTIAL.......1587
LIMITED SLIP DIFFERENTIAL.......1587
WA450-5L FRONT.......1589
WA480-5L FRONT AND REAR.......1589
WA450-5L REAR.......1590
OPERATION.......1591
TRAVELING IN A STRAIGHT LINE.......1591
WHEN TURNING.......1592
STANDARD DIFFERNTIAL.......1593
FRONT DIFFERENTIAL.......1593
REAR DIFFERENTIAL.......1594
OUTLINE.......1595
TRAVELING IN A STRAIGHT LINE.......1595
TURNING.......1595
FINAL DRIVE.......1596
WA450-5L.......1596
WA480-5L.......1597
OUTLINE.......1599
CENTER HINGE PIN.......1600
OUTLINE.......1600
STEERING PIPING.......1603
STEERING COLUMN.......1604
STEERING VALVE.......1605
OVERLOAD RELIEF VALVE.......1606
FUNCTION.......1606
OPERATION.......1606
STEERING RELIEF VALVE.......1607
FUNCTION.......1607
OPERATION OF STEERING RELIEF VALVE.......1608
OPERATION OF DEMAND VALVE.......1609
FLOW AMP.......1612
OPERATION OF FLOW AMP.......1612
OPERATION OF STEERING VALVE.......1615
NEUTRAL.......1615
TURNING RIGHT.......1616
TURNING LEFT.......1617
ORBITROL VALVE.......1618
OUTLINE.......1619
STRUCTURE.......1619
CONNECTION BETWEEN HAND PUMP AND SLEEVE.......1620
STOP VALVE.......1622
STEERING AND SWITCH PUMP.......1623
OUTLINE.......1623
AUXILIARY STEERING PUMP.......1625
FUNCTION.......1625
AUXILIARY STEERING MOTOR.......1626
FUNCTION.......1626
SPECIFICATIONS.......1626
STEERING CYLINDER.......1627
MOUNTING.......1627
CYLINDER.......1628
JOYSTICK STEERING LEVER.......1629
LEVER CONNECTIONS.......1629
STEERING SWITCH VALVE.......1630
OPERATION.......1630
STEERING LEVER VALVE.......1631
BRAKE SYSTEM.......1632
PIPING.......1632
BRAKE VALVE.......1633
LEFT PEDAL AND VALVE.......1633
RIGHT PEDAL AND VALVE.......1634
OUTLINE.......1635
OPERATION.......1635
CHARGE VALVE.......1639
FUNCTION.......1640
OPERATION.......1641
ACCUMULATOR.......1643
BETWEEN CHARGE VALVE AND BRAKE VALVE.......1643
SPECIFICATIONS.......1643
BETWEEN BRAKE VALVE AND BRAKE CYLINDER.......1644
SLACK ADJUSTER.......1645
OUTLINE.......1646
SPECIFICATIONS.......1646
OPERATION.......1647
BRAKES.......1648
FRONT.......1648
REAR.......1649
PARKING BRAKE.......1651
CONTROLS.......1651
OUTLINE.......1651
BRAKE PORTION.......1652
OUTLINE.......1652
SOLENOID VALVE.......1653
PARKING BRAKE APPLIED.......1653
PARKING BRAKE RELEASED.......1653
RELEASE VALVE.......1654
OUTLINE.......1654
HYDRAULIC PIPING.......1655
OUTLINE.......1656
WORK EQUIPMENT CONTROL LEVER.......1657
FOR PPC VALVE.......1657
FOR EPC VALVE.......1658
HYDRAULIC TANK.......1659
SPECIFICATIONS.......1659
BREATHER.......1660
SPECIFICATIONS.......1660
PREVENTION OF NEGATIVE PRESSURE IN TANK.......1660
PREVENTION OF PRESSURE RISE IN TANK.......1660
CONVERTER, EQUIPMENT AND PPC PUMPS.......1661
SAL (4)125+140+(1)22.......1661
OUTLINE.......1661
PPC RELIEF VALVE.......1662
OUTLINE.......1662
OPERATION.......1662
ECSS VALVE.......1663
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM.......1663
TRAVEL DAMPER VALVE.......1665
EQUIPMENT CONTROL VALVE.......1666
2 SPOOL VALVE.......1666
3 SPOOL VALVE.......1669
RELIEF VALVE.......1672
FUNCTION.......1672
OPERATION.......1672
SAFETY SUCTION VALVE.......1673
FUNCTION.......1673
OPERATION.......1673
SUCTION VALVE.......1674
FUNCTION.......1674
OPERATION.......1674
SAFETY SUCTION VALVE.......1674
FUNCTION.......1674
OPERATION.......1674
CUT OFF VALVE.......1676
FUNCTION.......1676
CUT OFF VALVE OPERATION.......1676
FLOAT SELECTOR AND UNLOAD VALVE.......1678
FUNCTION.......1678
OPERATION.......1678
BOOM AND BUCKET SPOOL HOLD POSITION.......1679
OPERATION.......1679
BOOM SPOOL RAISE POSITION.......1680
OPERATION.......1680
BOOM SPOOL LOWER POSITION.......1681
OPERATION.......1681
BOOM SPOOL FLOAT POSITION.......1682
OPERATION.......1682
BUCKET SPOOL DUMP POSITION.......1683
OPERATION.......1683
BUCKET SPOOL TILT POSITION.......1684
OPERATION.......1684
PPC VALVE FOR TWO LEVERS.......1685
OPERATION.......1687
NEUTRAL.......1687
FINE CONTROL MODE.......1688
PPC VALVE FOR MONO LEVER.......1690
OPERATION.......1692
NEUTRAL.......1692
FINE CONTROL.......1693
FLOAT.......1694
FLOAT RELEASED.......1694
EPC VALVE.......1695
FUNCTION.......1696
OPERATION.......1696
SHUT OFF VALVE.......1698
FUNCTION.......1698
COOLING FAN.......1699
MOTOR MODEL: LMF28.......1699
SPECIFICATIONS.......1699
FUNCTION.......1701
PRINCIPLE OF OPERATION.......1701
SUCTION VALVE.......1702
FUNCTION.......1702
OPERATION.......1702
FAN DIRECTION CHANGEOVER VALVE.......1703
DRIVE PUMP - MODEL: LPV3O.......1704
FUNCTION.......1706
STRUCTURE.......1706
OPERATION.......1707
SERVO VALVE.......1708
FUNCTION.......1709
SAFETY VALVE.......1710
FUNCTION.......1710
BOOM AND BUCKET LINKAGE.......1711
BUCKET.......1713
BUCKET POSITIONER, BOOM KICK OUT.......1714
BUCKET POSITIONER.......1715
BOOM KICK OUT.......1715
OPERATION OF PROXIMITY SWITCH.......1715
BOOM RAISE.......1715
BUCKET TILT.......1717
WORK EQUIPMENT CYLINDER.......1720
BOOM CYLINDER.......1720
BUCKET CYLINDER.......1720
CAB.......1722
AIR CONDITIONER.......1723
MACHINE MONITORING SYSTEM.......1724
OUTLINE.......1724
MODE INDICATIONS.......1724
INDIVIDUAL CIRCUIT DIAGRAMS.......1726
STARTING AND LIGHTING.......1726
LOAD METER.......1726
SENSING FUNCTIONS.......1727
POWER SUPPLY AND NETWORK.......1728
MACHINE MONITOR.......1732
STANDARD STYLE.......1732
LOAD METER STYLE.......1733
TABLE OF MONITOR INDICATION ITEMS.......1734
SETTING OF THE MACHINE MONITOR.......1744
ADJUSTMENT PROCEDURES.......1746
SERVICE MODE FUNCTIONS.......1747
ITEMS RELATED TO THE FAULT HISTORY OF ELECTRIC SYSTEM.......1751
ITEMS RELATED TO THE FAULT HISTORY OF MACHINE SYSTEM.......1753
ITEMS RELATED TO MAINTENANCE MONITOR.......1755
ENGINE CYLINDER CUT OUT FUNCTION.......1757
REAL TIME MONITORING FUNCTION.......1759
REAL TIME MONITORING ITEMS.......1763
LOAD METER FUNCTION.......1774
OUTLINE.......1774
MACHINE SETTING.......1783
TRANSMISSION CONTROL SYSTEM.......1811
CONTROL FUNCTION.......1812
ELECTRIC CIRCUIT DIAGRAM - STD.......1836
ELECTRIC CIRCUIT DIAGRAM - OPT.......1838
TRANSMISSION CONTROLLER.......1840
INPUT AND OUTPUT SIGNALS.......1840
DEUTSCH-24P - CNL61.......1840
DEUTSCH-40P[1] - CNL62.......1841
DEUTSCH-40P[2] - CNL63.......1841
WORK EQUIPMENT CONTROL SYSTEM.......1842
SYSTEM DIAGRAM.......1842
WORK EQUIPMENT CONTROL.......1843
ELECTRIC LEVER CONTROL.......1843
DETENT CONTROL.......1844
REMOTE POSITIONER CONTROL.......1846
FUNCTIONS.......1846
STOP THE BOOM RAISE OPERATION.......1846
CONTROL ITEMS.......1848
SEMI AUTO DIG CONTROL.......1849
STARTING CONDITIONS FOR SEMI AUTO DIG.......1850
STARTING SEMI AUTO DIG.......1850
TERMINATION OF SEMI AUTO DIG.......1850
SEMI AUTO DIG MODE.......1851
JOYSTICK STEERING CONTROL.......1852
STEERING CONTROL.......1853
MODULATION CONTROL.......1853
CALIBRATION FUNCTION.......1854
ELECTRIC CIRCUIT DIAGRAM.......1855
WORK EQUIPMENT CONTROLLER.......1857
INPUT AND OUTPUT SIGNALS.......1857
DEUTSCH-24P - CNL71.......1857
DEUTSCH-40P[1] - CNL72.......1858
DEUTSCH-40P[2] - CNL73.......1858
ELECTRIC TRANSMISSION CONTROL.......1859
FUNCTIONS.......1860
COMBINATION SWITCH.......1861
FUNCTIONS.......1861
OVERVIEW.......1861
OPERATION.......1862
KICK DOWN HOLD SWITCH.......1863
FUNCTIONS.......1863
ENGINE START CIRCUIT.......1864
FUNCTION.......1864
OPERATION.......1865
ENGINE STOP CIRCUIT.......1866
OPERATION.......1866
PARKING BRAKE CIRCUIT.......1867
OPERATION.......1867
STARTING SWITCH IN OFF POSITION.......1867
STARTING SWITCH IN ON POSITION........1867
TURN SIGNAL AND HAZARD LAMP CIRCUIT.......1869
OPERATION.......1869
STARTING SWITCH IN OFF POSITION.......1869
STARTING SWITCH IN ON POSITION.......1869
BACK UP LAMP AND STOP LAMP CIRCUIT.......1871
OPERATION.......1871
STOP LAMP CIRCUIT.......1871
BACK UP LAMP CIRCUIT.......1872
SMALL LAMP AND HEAD LAMP CIRCUIT.......1873
OPERATION.......1873
WORK LAMP CIRCUIT.......1874
OPERATION.......1874
HORN CIRCUIT.......1875
OPERATION.......1875
WIPER WASHER CIRCUIT.......1876
OPERATION.......1876
FRONT WIPER CIRCUIT.......1876
REAR WIPER CIRCUIT.......1877
SENSORS.......1878
ENGINE AND MACHINE SPEED SENSOR.......1878
FUNCTION.......1878
ENGINE OIL PRESSURE SENSOR.......1878
FUNCTION.......1878
ENGINE OIL LEVEL SENSOR.......1879
FUNCTION.......1879
TEMPERATURE SENSOR.......1879
ENGINE COOLANT, CONVERTER, HYDRAULIC, TRANSMISSION OR BRAKE OIL.......1879
TRANSMISSION CUT OFF PRESSURE SENSOR.......1880
FUNCTION.......1880
RADIATOR COOLANT LEVEL SENSOR.......1881
FUNCTION.......1881
FUEL LEVEL SENSOR.......1882
FUNCTION.......1882
BOOM ANGLE SENSOR FOR LOAD METER.......1883
FUNCTION.......1883
AIR CLEANER CLOGGING SENSOR.......1884
FUNCTION.......1884
PRESSURE SENSOR FOR LOAD METER.......1884
FUNCTION.......1884
BATTERY LIQUID SENSOR.......1885
FUNCTION.......1885
RELAYS.......1886
20 TESTING, ADJUSTING AND TROUBLESHOOTING.......1887
STANDARD VALUE TABLE FOR ENGINE.......1889
STANDARD VALUE TABLE FOR CHASSIS.......1890
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING.......1897
ENGINE COMPONENTS.......1899
MEASURING EXHAUST SMOKE.......1899
MEASURING EXHAUST TEMPERATURE.......1899
ADJUSTING VALVE CLEARANCE.......1899
MEASURING COMPRESSION PRESSURE.......1899
MEASURING CRANCASE PRESSURE.......1899
MEASURING ENGINE OIL PRESSURE.......1899
MEASURING BOOST PRESSURE.......1899
MEASURING FUEL PRESSURE.......1899
ADJUSTING ENGINE SPEED SENSOR.......1899
BLEEDING AIR FROM FUEL SYSTEM.......1899
MEASURING ENGINE SPEED.......1900
ADJUSTING ACCELERATOR PEDAL.......1902
POTENTIOMETER.......1902
MICROSWITCH.......1904
ADJUSTING TRANSMISSION SPEED SENSOR.......1905
POWER TRAIN OIL PRESSURE.......1906
FLUSHING.......1910
TORQUE CONVERTER, TRANSMISSION AND HYDRAULIC CIRCUIT.......1910
TRANSMISSION VALVE FAILS.......1911
MOVING MACHINE.......1911
STEERING CONTROL.......1913
STEERING OIL PRESSURE.......1914
BRAKE SYSTEM.......1916
MEASURING BRAKE OIL PRESSURE.......1916
TESTING WEAR OF WHEEL BRAKE DISC.......1918
BLEEDING AIR FROM BRAKE CIRCUIT.......1919
TESTING WEAR OF PARKING BRAKE DISC.......1920
MANUAL RELEASE METHOD FOR PARKING BRAKE.......1921
TESTING HYDRAULIC FAN.......1922
ACCUMULATOR CHARGE PRESSURE.......1923
PPC OIL PRESSURE.......1925
WORK EQUIPMENT HYDRAULIC PRESSURE.......1928
BUCKET POSITIONER.......1930
LIFT ARM KICK-OUT.......1931
PROXIMITY SWITCH ACTUATION.......1932
ADJUSTING MACHINE MONITOR.......1933
LOAD METER.......1936
LOAD METER CALIBRATION.......1937
NO LOAD ZERO POINT ADJUSTMENT (SUPPLEMENTAL EXPLANATIONS).......1937
LOAD ZERO POINT ADJUSTMENT (SUPPLEMENTARY EXPLANATIONS).......1938
BLEEDING AIR.......1941
RELEASING REMAINING PRESSURE.......1942
IN HYDRAULIC CIRCUIT.......1942
IN TRAVEL DAMPER CIRCUIT.......1943
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT.......1944
PM-CLINIC INSPECTION TABLE.......1945
TROUBLESHOOTING GENERAL.......1949
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......1950
SEQUENCE OF EVENTS IN TROUBLESHOOTING.......1952
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.......1953
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT.......1953
HANDLING CONTROL BOX.......1958
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.......1959
CHECKS BEFORE TROUBLESHOOTING.......1961
EQUIPMENT FOR TROUBLESHOOTING ELECTRICAL SYSTEM.......1962
TROUBLESHOOTING MACHINE MONITOR.......1963
SPECIAL FUNCTIONS OF MACHINE MONITOR.......1964
FLOW OF MODES AND FUNCTIONS.......1965
FAILURE CODE TABLE.......1973
MONITORING CODE TABLE.......1987
USING TROUBLESHOOTING CHARTS.......1999
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.......2006
T-ADAPTER TABLE.......2027
TROUBLESHOOTING OF ENGINE CONTROL SYSTEM (ENG MODE).......2031
CONNECTOR TYPES AND INSTALLATION LOCATIONS.......2034
CONNECTOR ARRANGEMENT LOCATIONS.......2041
ENGINE CONTROL SYSTEM DIAGRAM.......2047
ERROR CODE [A000N1].......2049
ENGINE OVERRUNS (N1).......2049
ERROR CODE [AD00L2].......2050
COMMON RAIL HIGHER THAN SET VALUE.......2050
ERROR CODE [AD10L3].......2051
FUEL SUPPLY PUMP CANNOT BE CONTROLLED.......2051
ERROR CODE [AD00MA].......2054
FUNCTION OF COMMON RAIL IS DEFECTIVE.......2054
ERROR CODE [AD10MA].......2055
FUEL SUPPLY PUMP IS DEFECTIVE.......2055
ERROR CODE [AD10MB].......2056
FUEL SUPPLY PUMP FLOW LOWERED.......2056
ERROR CODE [AD11KA or AD11KB].......2057
OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM.......2057
ERROR CODE [AD51KA or AD51KB].......2059
OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM.......2059
ERROR CODE [ADA1KA].......2061
OPEN IN NO. 1 INJECTOR SOLENOID VALVE.......2061
ERROR CODE [ADAZKB].......2063
SHORT CIRCUIT IN NO. 1, 2, 3 INJECTOR SOLENOID VALVE.......2063
ERROR CODE [ADB1KA].......2065
OPEN IN NO. 2 INJECTOR SOLENOID VALVE.......2065
ERROR CODE [ADC1KA].......2067
OPEN IN NO. 3 INJECTOR SOLENOID VALVE.......2067
ERROR CODE [ADD1KA].......2069
OPEN IN NO. 4 INJECTOR SOLENOID VALVE.......2069
ERROR CODE [ADDZKB].......2071
SHORT CIRCUIT IN NO. 4, 5, 6 INJECTOR SOLENOID VALVE.......2071
ERROR CODE [ADE1KA].......2073
OPEN IN NO. 5 INJECTOR SOLENOID VALVE.......2073
ERROR CODE [ADF1KA].......2075
OPEN IN NO. 6 INJECTOR SOLENOID VALVE.......2075
ERROR CODE [D182KZ].......2077
OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL.......2077
ERROR CODE [D1D0KB].......2079
SHORT CIRCUIT IN VOLTAGE LOAD POWER SUPPLY.......2079
ERROR CODE [DB20KT].......2081
CONTROLLER POWER SUPPLY (NSW) VOLTAGE IS LOW.......2081
ERROR CODE [AB20KT].......2083
TROUBLE IN DRIVE CIRCUIT IN CONTROLLER.......2083
ERROR CODE [DB22KK].......2085
ENGINE CONTROLLER LOAD POWER SUPPLY (SW) 1.......2085
ERROR CODE [DB29KQ].......2087
NONCONFORMANCE OF MODEL SELECTION SIGNALS IN ENGINE CONTROLLER CONNECTING WIRING HARNESS.......2087
ERROR CODE [DB2AMA].......2089
FUNCTION OF Q ADJUSTMENT SWITCH OF ENGINE CONTROLLER IS DEFECTIVE.......2089
ERROR CODE [DD11KB].......2090
TROUBLE IN INPUT OF STARTING SWITCH C (IGN C1).......2090
ERROR CODE [DGE3L6].......2092
TROUBLE IN WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM.......2092
ERROR CODE [DGE4KX].......2094
TROUBLE IN FUEL TEMPERATURE SENSOR SYSTEM.......2094
ERROR CODE [DH30KX].......2096
TROUBLE IN BOOST PRESSURE SENSOR SYSTEM.......2096
ERROR CODE [DH40KX].......2098
TROUBLE IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM.......2098
ERROR CODE [DK10KX].......2100
TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM.......2100
ERROR CODE [DLE3LC].......2102
TROUBLE IN ENGINE NE SPEED SENSOR SYSTEM.......2102
ERROR CODE [DLH1LC].......2103
TROUBLE IN ENGINE G SPEED SENSOR SYSTEM.......2103
ERROR CODE [ENG-1].......2104
ENGINE DOES NOT START.......2104
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE).......2109
CONNECTOR TYPES AND INSTALLATION POSITIONS.......2115
CONNECTOR LAYOUT DRAWING.......2122
TRANSMISSION RELATED SYSTEM DIAGRAM.......2128
ERROR CODE [1500L1].......2131
DOUBLE ENGAGEMENT DETECTED.......2131
ERROR CODE [15SAL1].......2132
F-ECMV FILL SWITCH SYSTEM SHORTED.......2132
ERROR CODE [15SALH].......2133
F_ECMV FILL SWITCH SYSTEM OPEN.......2133
ERROR CODE [15SBL1].......2134
R_ECMV FILL SWITCH SYSTEM SHORTED.......2134
ERROR CODE [15SBLH].......2136
R_ECMV FILL SWITCH SYSTEM OPEN.......2136
ERROR CODE [15SEL1].......2137
1ST_ECMV FILL SWITCH SYSTEM SHORTED.......2137
ERROR CODE [15SELH].......2139
1ST_ECMV FILL SWITCH SYSTEM OPEN.......2139
ERROR CODE [15SFL1].......2141
2ND_ECMV FILL SWITCH SYSTEM SHORTED.......2141
ERROR CODE [15SFLH].......2143
2ND_ECMV FILL SWITCH SYSTEM OPEN.......2143
ERROR CODE [15SGL1].......2145
3RD_ECMV FILL SWITCH SYSTEM SHORTED.......2145
ERROR CODE [15SGLH].......2147
3RD_ECMV FILL SWITCH SYSTEM OPEN.......2147
ERROR CODE [15SHL1].......2149
4TH_ECMV FILL SWITCH SYSTEM SHORTED.......2149
ERROR CODE [15SHLH].......2151
4TH_ECMV FILL SWITCH SYSTEM OPEN.......2151
ERROR CODE [15SJL1].......2153
LOCKUP_ECMV FILL SWITCH SYSTEM SHORTED.......2153
ERROR CODE [15SJLH].......2154
LOCKUP_ECMV FILL SWITCH SYSTEM OPEN.......2154
ERROR CODE [989F00].......2155
TRANSMISSION PROTECTION CAUTION.......2155
ERROR CODE [989G00].......2156
FNR LEVER PRIORITY CAUTION.......2156
ERROR CODE [B@C7NS].......2157
REAR BRAKE COOLING OIL OVERHEATING FAULT.......2157
ERROR CODE [D150KA].......2159
EMERGENCY STEERING RELAY OUTPUT SYSTEM OPEN.......2159
ERROR CODE [D150KB].......2160
EMERGENCY STEERING RELAY OUTPUT SYSTEM SHORTED.......2160
ERROR CODE [D160KA].......2161
EMERGENCY STEERING RELAY OUTPUT SYSTEM OPEN.......2161
ERROR CODE [D160KB].......2162
BACKUP LAMP RELAY OUTPUT SYSTEM SHORTED.......2162
ERROR CODE [D191KA].......2163
NEUTRAL SAFETY RELAY OUTPUT SYSTEM OPEN.......2163
ERROR CODE [D191KB].......2165
NEUTRAL SAFETY RELAY OUTPUT SYSTEM SHORTED.......2165
ERROR CODE [D192KA].......2167
BOOM DAMPER RELAY OUTPUT SYSTEM OPEN.......2167
ERROR CODE [D192KB].......2168
LIFT ARM DAMPER RELAY OUTPUT SYSTEM SHORTED.......2168
ERROR CODE [DAQ0KK].......2169
CONTROLLER POWER SUPPLY FAULT.......2169
ERROR CODE [DAQ2KK].......2170
DEFECTIVE SOLENOID POWER SUPPLY SYSTEM.......2170
ERROR CODE [DAQ9KQ].......2172
MODEL SELECTION SIGNAL MISMATCH.......2172
ERROR CODE [DDK3KA].......2173
RIGHT FNR SIGNAL INPUT FAULT.......2173
ERROR CODE [DDK3KB].......2175
MULTIPLE RIGHT FNR SIGNAL INPUT FAULTS.......2175
ERROR CODE [DDK6KA].......2177
FORWARD-REVERSE LEVER SIGNAL FAULT.......2177
ERROR CODE [DDK6KB].......2179
MULTIPLE FORWARD-REVERSE LEVER SIGNAL INPUT FAULT.......2179
ERROR CODE [DDS5KA].......2181
STEERING PRESSURE SWITCH OPEN.......2181
ERROR CODE [DDS5KB].......2182
STEERING PRESSURE SWITCH SHORTED.......2182
ERROR CODE [DDT0L4].......2184
MANUAL/AUTO-SHIFT SELECTOR SWITCH SELECTION FAILURE.......2184
ERROR CODE [DDT4LD].......2186
GROUND FAULT ON TRANSMISSION CUT-OFF SETTING SWITCH.......2186
ERROR CODE [DDW9LD].......2187
SHORT IN KICKDOWN SWITCH SYSTEM.......2187
ERROR CODE [DDWLLD].......2188
GROUND FAULT IN HOLD SWITCH SYSTEM.......2188
ERROR CODE [DF10KA].......2189
NO INPUT IN GEAR SHIFT LEVER SYSTEM.......2189
ERROR CODE [DF10KB].......2191
MULTIPLE GEAR SHIFT LEVER SIGNALS OR NO GEAR SHIFT LEVER SIGNAL.......2191
ERROR CODE [DGF1KX].......2193
TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM FAILURE.......2193
ERROR CODE [DGR2KA].......2194
REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM OPEN.......2194
ERROR CODE [DGR2KB].......2196
GROUND FAULT IN REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM.......2196
ERROR CODE [DHT1KX].......2197
TRANSMISSION CUT-OFF (LEFT BRAKE PRESSURE SENSOR) SIGNAL OPEN.......2197
ERROR CODE [DLE2KA].......2198
ENGINE SPEED SENSOR OPEN.......2198
ERROR CODE [DLE2LC].......2199
ENGINE SPEED SENSOR SHORTED.......2199
ERROR CODE [DLT3KA].......2200
SPEED SENSOR SYSTEM OPEN.......2200
ERROR CODE [DT20KB].......2201
GROUND FAULT IN BUILT-IN INDICATOR LAMP SYSTEM ON TRANSMISSION CUT-OFF SWITCH.......2201
ERROR CODE [DW7BKA].......2202
FAN REVERSE SOLENOID SYSTEM OPEN.......2202
ERROR CODE [DW7BKB].......2203
FAN REVERSE SOLENOID SYSTEM SHORTED.......2203
ERROR CODE [DW7CKA].......2204
SWITCH PUMP CUT-OFF RELAY OPEN.......2204
ERROR CODE [DW7CKB].......2205
SWITCH PUMP CUT-OFF RELAY GROUND FAULT.......2205
ERROR CODE [DX16KA].......2206
FAN PUMP EPC SOLENOID SYSTEM OPEN.......2206
ERROR CODE [DX16KB].......2207
FAN PUMP EPC SOLENOID SYSTEM GROUND FAULT.......2207
ERROR CODE [DXH1KA].......2208
LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM OPEN.......2208
ERROR CODE [DXH1KB].......2209
LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM SHORTED.......2209
ERROR CODE [DXH4KA].......2210
1ST_ECMV SOLENOID SYSTEM OPEN.......2210
ERROR CODE [DXH4KB].......2211
1ST_ECMV SOLENOID SYSTEM SHORTED.......2211
ERROR CODE [DXH5KA].......2212
2ND_ECMV SOLENOID SYSTEM OPEN.......2212
ERROR CODE [DXH5KB].......2213
2ND_ECMV SOLENOID SYSTEM SHORTED.......2213
ERROR CODE [DXH6KA].......2214
3RD_ECMV SOLENOID SYSTEM OPEN.......2214
ERROR CODE [DXH6KB].......2215
3RD_ECMV SOLENOID SYSTEM SHORTED.......2215
ERROR CODE [DXH7KA].......2216
R_ECMV SOLENOID SYSTEM OPEN.......2216
ERROR CODE [DXH7KB].......2217
R_ECMV SOLENOID SYSTEM GROUND FAULT.......2217
ERROR CODE [DXH8KA].......2218
F_ECMV SOLENOID SYSTEM OPEN.......2218
ERROR CODE [DXH8KB].......2219
F_ECMV SOLENOID SYSTEM GROUND FAULT.......2219
ERROR CODE [DXHHKA].......2220
4TH_ECMV SOLENOID SYSTEM OPEN.......2220
ERROR CODE [DXHHKB].......2221
4TH_ECMV SOLENOID SYSTEM SHORTED.......2221
ERROR CODE [DY30MA].......2222
MOTOR DRIVEN EMERGENCY STEERING PUMP ERROR (MALFUNCTION IN MANUAL MODE).......2222
ERROR CODE [DY30MC].......2224
MOTOR DRIVEN EMERGENCY STEERING PUMP ERROR (MALFUNCTION IN MANUAL MODE).......2224
ACTION CODE [TM-1].......2226
OPEN OR SHORT IN KICKDOWN SWITCH SYSTEM.......2226
ACTION CODE [TM-2].......2228
OPEN OR SHORT IN HOLD SWITCH (NO HOLD CONTROL PERFORMED BY PRESSING HOLD SWITCH).......2228
ACTION CODE [TM-3].......2230
TORQUE CONVERTER LOCK-UP SWITCH SYSTEM FAILURE (NO LOCK-UP PERFORMED OR NO LOCK-UP CANCELLATION PERFORMED).......2230
ACTION CODE [TM-4].......2232
NEUTRALIZER SIGNAL (PARKING BRAKE SWITCH SIGNAL) SYSTEM FAILURE.......2232
ACTION CODE [TM-5].......2234
EMERGENCY STEERING SWITCH (MOTOR DRIVEN EMERGENCY STEERING OPERATION SWITCH) SIGNAL SYSTEM FAILURE.......2234
ACTION CODE [TM-6].......2236
OPEN OR SHORT IN TRANSMISSION CUT-OFF SWITCH SYSTEM.......2236
ACTION CODE [TM-7].......2237
OPEN OR SHORT IN TRANSMISSION CUT-OFF SETTING SWITCH SYSTEM.......2237
ACTION CODE [TM-8].......2238
TRANSMISSION CUT-OFF (LEFT BRAKE SENSOR) SIGNAL SHORTED.......2238
ACTION CODE [TM-9-A].......2239
JOYSTICK SHIFT UP/SHIFT DOWN SWITCH SYSTEM FAILURE.......2239
ACTION CODE [TM-9-B].......2241
FNR SWITCH MODE CHANGE OVER SWITCH SYSTEM FAILURE.......2241
ACTION CODE [TM-10].......2243
START SWITCH C (IGN C) SIGNAL SYSTEM FAILURE.......2243
ACTION CODE [TM-11].......2245
JOYSTICK ON/OFF CHANGE OVER SWITCH SYSTEM FAILURE.......2245
ACTION CODE [TM-12].......2247
OPEN OR SHORT IN ENGINE POWER MODE SWITCH.......2247
ACTION CODE [TM-13].......2248
OPEN OR SHORT IN TRAVEL DAMPER ON/OFF SWITCH.......2248
ACTION CODE [TM-14].......2249
OPEN OR SHORT IN HYDRAULIC FAN REVERSE SWITCH SIGNAL SYSTEM.......2249
ACTION CODE [TM-15].......2251
SHORT IN MOTOR DRIVEN EMERGENCY STEERING RELAY OUTPUT SYSTEM.......2251
ACTION CODE [TM-16].......2252
SHORT IN TRAVEL DAMPER RELAY OUTPUT SYSTEM.......2252
ACTION CODE [TM-17].......2253
SWITCH PUMP CUT-OFF RELAY OUTPUT SYSTEM SHORTED.......2253
ACTION CODE [TM-18].......2254
BACK LAMP RELAY OUTPUT SYSTEM SHORTED.......2254
ACTION CODE [TM-19].......2255
NEUTRAL OUTPUT SYSTEM SHORTED.......2255
ACTION CODE [TM-20].......2257
F_ECMV SOLENOID SYSTEM SHORTED.......2257
ACTION CODE [TM-21].......2258
R_ECMV SOLENOID SYSTEM SHORTED.......2258
ACTION CODE [TM-22].......2259
1ST_ECMV SOLENOID SYSTEM SHORTED.......2259
ACTION CODE [TM-23].......2260
2ND_ECMV SOLENOID SYSTEM SHORTED.......2260
ACTION CODE [TM-24].......2261
3RD_ECMV SOLENOID SYSTEM SHORTED.......2261
ACTION CODE [TM-25].......2262
4TH_ECMV SOLENOID SYSTEM SHORTED.......2262
ACTION CODE [TM-26].......2263
LOCK-UP ECMV SOLENOID SYSTEM SHORTED.......2263
ACTION CODE [TM-27].......2264
FAN PUMP EPC SOLENOID SYSTEM SHORTED.......2264
ACTION CODE [TM-28].......2265
FAN REVERSE SOLENOID SYSTEM SHORTED.......2265
ACTION CODE [TM-29].......2266
SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM FAILURE.......2266
ACTION CODE [TM-30].......2267
TRAVEL DAMPENER SOLENOID SHORTED OR OPEN.......2267
TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (WRK MODE).......2269
CONNECTOR TYPES AND INSTALLATION POSITIONS.......2273
CONNECTOR LAYOUT DRAWING.......2280
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM.......2286
ERROR CODE [D193KA].......2289
JOYSTICK STEERING CONTROL SYSTEM OPEN.......2289
ERROR CODE [D193KB].......2291
JOYSTICK STEERING CONTROL SYSTEM SHORTED.......2291
ERROR CODE [DB90KK].......2293
POWER SUPPLY TO WORK EQUIPMENT CONTROLLER IS LOW.......2293
ERROR CODE [DB92KK].......2295
CONTROLLER POWER TO THE SOLENOID SYSTEM IS LOW.......2295
ERROR CODE [DB95KX].......2297
DEFECTIVE 5 VOLT POWER SUPPLY.......2297
ERROR CODE [DD1ALD].......2300
SHORT OR OPEN IN REMOTE POSITIONER UP SET SWITCH.......2300
ERROR CODE [DD1BLD].......2302
SHORT OR OPEN IN REMOTE POSITIONER DWN SET SWITCH.......2302
ERROR CODE [DFAOKM].......2304
DEFECTIVE NEUTRAL CAUTION FOR JOYSTICK WORK EQUIPMENT.......2304
ERROR CODE [DK59KA].......2306
DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER.......2306
ERROR CODE [DK59KY].......2308
DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER.......2308
ERROR CODE [DK59L8].......2310
DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER.......2310
ERROR CODE [DK5AKA].......2312
DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER.......2312
ERROR CODE [DK5AKY].......2314
DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER.......2314
ERROR CODE [DK5BKA].......2316
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER.......2316
ERROR CODE [DK5BKY].......2318
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER.......2318
ERROR CODE [DK5BL8].......2320
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER.......2320
ERROR CODE [DK5CKA].......2322
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER.......2322
ERROR CODE [DK5CKY].......2324
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER.......2324
ERROR CODE [DK5DKA].......2326
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER.......2326
ERROR CODE [DK5DKY].......2328
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER.......2328
ERROR CODE [DK5DL8].......2330
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER.......2330
ERROR CODE [DK5EKA].......2332
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER.......2332
ERROR CODE [DK5EKY].......2334
OPEN OR SHORT IN BUCKET EPC LEVER POTENTIOMETER.......2334
ERROR CODE [DK5FKA].......2336
OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER.......2336
ERROR CODE [DK5FKY].......2338
OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER.......2338
ERROR CODE [DK5FKM].......2340
JOYSTICK STEERING EPC LEVER NEUTRAL SYSTEM.......2340
ERROR CODE [DK5FL8].......2341
OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER.......2341
ERROR CODE [DK5GKA].......2343
OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER.......2343
ERROR CODE [DK5GKY].......2345
OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER.......2345
ERROR CODE [DKAOKA].......2347
OPEN OR SHORT IN LIFT ARM ANGLE SENSOR SYSTEM.......2347
ERROR CODE [DKAOKY].......2349
OPEN OR SHORT IN LIFT ARM ANGLE SENSOR SYSTEM.......2349
ERROR CODE [DLE2LC].......2351
DEFECTIVE ENGINE SPEED SENSOR SYSTEM.......2351
ERROR CODE [DLT3LC].......2352
DEFECTIVE ENGINE SPEED SENSOR SYSTEM.......2352
ERROR CODE [DUM1KB].......2353
REMOTE POSITIONER RAISE LAMP SYSTEM FAULT.......2353
ERROR CODE [DUM2KB].......2355
REMOTE POSITIONER LOWER LAMP SYSTEM FAULT.......2355
ERROR CODE [DW4PKA].......2357
OPEN IN LIFT ARM RAISE EPC SOLENOID SYSTEM.......2357
ERROR CODE [DW4PKB].......2358
SHORT IN LIFT ARM RAISE EPC SOLENOID SYSTEM.......2358
ERROR CODE [DW4QKA].......2359
OPEN IN LIFT ARM LOWER EPC SOLENOID SYSTEM.......2359
ERROR CODE [DW4QKB].......2360
SHORT IN LIFT ARM LOWER EPC SOLENOID SYSTEM.......2360
ERROR CODE [DW4RKA].......2361
OPEN IN BUCKET TILT EPC SOLENOID SYSTEM.......2361
ERROR CODE [DW4RKB].......2362
SHORT IN BUCKET TILT EPC SOLENOID SYSTEM.......2362
ERROR CODE [DW4SKA].......2363
OPEN IN BUCKET DUMP EPC SOLENOID SYSTEM.......2363
ERROR CODE [DW4SKB].......2364
SHORT IN BUCKET DUMP EPC SOLENOID SYSTEM.......2364
ERROR CODE [DWM1KA].......2365
OPEN IN NEUTRAL LOCK EPC SOLENOID SYSTEM.......2365
ERROR CODE [DWM1KB].......2366
SHORT IN neutral lock EPC SOLENOID SYSTEM.......2366
ERROR CODE [DWN6KB].......2367
SHORT IN LIFT ARM RAISE EPC LEVER DETENT.......2367
ERROR CODE [DWN6KA].......2369
OPEN IN LIFT ARM RAISE EPC LEVER DETENT.......2369
ERROR CODE [DWN7KA].......2371
OPEN IN LIFT ARM FLOAT EPC LEVER DETENT.......2371
ERROR CODE [DWN7KB].......2373
SHORT IN LIFT ARM FLOAT EPC LEVER DETENT.......2373
ERROR CODE [DWN8KA].......2375
OPEN OR SHORT IN BUCKET TILT DETENT.......2375
ERROR CODE [DWN8KB].......2377
OPEN OR SHORT IN BUCKET TILT DETENT.......2377
ERROR CODE [DXHJKA].......2379
OPEN IN 3RD VALVE EXTENSION EPC SOLENOID SYSTEM.......2379
ERROR CODE [DXHJKB].......2380
SHORT IN 3RD VALVE EXTENSION EPC SOLENOID SYSTEM.......2380
ERROR CODE [DXHKKA].......2381
OPEN IN 3RD VALVE RETRACTION EPC SOLENOID SYSTEM.......2381
ERROR CODE [DXHKKB].......2382
SHORT IN 3RD VALVE RETRACTION EPC SOLENOID SYSTEM.......2382
ERROR CODE [DXHLKA].......2383
JOYSTICK STEERING RIGHT HAND CONTROL SYSTEM OPEN.......2383
ERROR CODE [DXHLKB].......2385
JOYSTICK STEERING RIGHT HAND CONTROL SYSTEM SHORTED.......2385
ERROR CODE [DXHMKA].......2387
JOYSTICK STEERING LEFT HAND CONTROL SYSTEM OPEN.......2387
ERROR CODE [DXHMKB].......2389
JOYSTICK STEERING LEFT HAND CONTROL SYSTEM SHORTED.......2389
WRK-1.......2391
DEFECTIVE LIFT ARM LOCK SWITCH SYSTEM.......2391
WRK-2.......2392
DEFECTIVE REMOTE POSITIONER RAISE SWITCH.......2392
WRK-3.......2394
DEFECTIVE REMOTE POSITIONER LOWER SWITCH.......2394
WRK-4.......2396
DEFECTIVE REMOTE POSITIONER RAISE SWITCH.......2396
WRK-5.......2398
DEFECTIVE REMOTE POSITIONER LOWER ON-OFF SWITCH.......2398
WRK-6.......2400
DEFECTIVE BUCKET CYLINDER PROXIMITY SWITCH SYSTEM.......2400
WRK-7.......2402
OPEN OR SHORT IN BUCKET CYLINDER FULL STROKE SYSTEM.......2402
WRK-8.......2404
DEFECTIVE SEMI-AUTOMATIC DIGGING SELECTION SWITCH.......2404
WRK-9.......2406
DEFECTIVE SEMI-AUTOMATIC DIGGING SELECTION SWITCH.......2406
WRK-10.......2408
DEFECTIVE JOYSTICK ON/OFF SWITCH.......2408
WRK-11.......2410
DEFECTIVE JOYSTICK HI/LO SWITCH.......2410
WRK-12.......2412
JOYSTICK STEERING LEFT HAND CONTROL SYSTEM SHORTED.......2412
WRK-13.......2414
OPEN OR SHORT IN LIFT ARM RAISE EPC LEVER DETENT.......2414
WRK-14.......2416
OPEN IN LIFT ARM FLOAT EPC LEVER DETENT.......2416
WRK-15.......2418
OPEN OR SHORT IN BUCKET TILT DETENT.......2418
WRK-16.......2419
SHORT IN NEUTRAL LOCK EPC SOLENOID SYSTEM.......2419
WRK-17.......2420
SHORT IN LIFT ARM RAISE EPC SOLENOID SYSTEM.......2420
WRK-18.......2421
SHORT IN LIFT ARM LOWER EPC SOLENOID SYSTEM.......2421
WRK-19.......2422
SHORT IN BUCKET TILT EPC SOLENOID SYSTEM.......2422
WRK-20.......2423
SHORT IN BUCKET DUMP EPC SOLENOID SYSTEM.......2423
WRK-21.......2424
SHORT IN 3RD VALVE EXTENSION EPC SOLENOID SYSTEM.......2424
WRK-22.......2425
SHORT IN 3RD VALVE RETRACTION EPC SOLENOID SYSTEM.......2425
WRK-23.......2426
OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER.......2426
WRK-24.......2428
OPEN OR SHORT IN STEERING EPC LEVER POTENTIOMETER.......2428
WRK-25.......2430
DEFECTIVE BUCKET POSITIONER LIFT ARM KICK-OUT FUNCTION.......2430
WRK-26.......2433
DEFECTIVE BUCKET POSITIONER LIFT ARM KICK-OUT FUNCTION.......2433
WRK-27.......2436
DEFECTIVE BUCKET LEVER FUNCTION.......2436
WRK-28.......2439
DEFECTIVE LIFT ARM FLOAT FUNCTION.......2439
TROUBLESHOOTING MACHINE MONITOR PANEL SYSTEM (MON MODE).......2443
CONNECTOR TYPES AND INSTALLATION LOCATIONS.......2447
CONNECTOR LAYOUT DRAWING.......2454
MONITOR SYSTEM DIAGRAM.......2460
ERROR CODE [2F00KM].......2464
DRAGGING PARKING BRAKE.......2464
ERROR CODE [2G42ZG].......2466
ACCUMULATOR OIL PRESSURE (FRONT CIRCUIT) LOW.......2466
ERROR CODE [2G43ZG].......2468
ACCUMULATOR OIL PRESSURE (REAR BRAKE CIRCUIT) LOW.......2468
ERROR CODE [AA1ANX].......2470
AIR CLEANER 1 CLOGGED.......2470
ERROR CODE [AB00L6].......2472
DEFECTIVE BATTERY CHARGING CIRCUIT (ALTERNATOR TERMINAL R SIGNAL DETECTED WHEN ENGINE STOPPED).......2472
ERROR CODE [AB00MA].......2474
DEFECTIVE BATTERY CHARGING CIRCUIT (NO ALTERNATOR TERMINAL R SIGNAL DETECTED, DETECTION FAILURE).......2474
ERROR CODE [B@BAZG].......2476
ENGINE OIL PRESSURE LOW.......2476
ERROR CODE [B@BAZK].......2478
ENGINE OIL LEVEL LOW.......2478
ERROR CODE [B@BCZK].......2480
ALARM INDICATING LOW COOLANT LEVEL.......2480
ERROR CODE [B@BCNS].......2482
ENGINE COOLANT TEMPERATURE OVERHEATING.......2482
ERROR CODE [B@HANS].......2484
HYDRAULIC OIL TEMPERATURE OVERHEATING.......2484
ERROR CODE [B@CENS].......2486
TORQUE CONVERTER OIL TEMPERATURE OVERHEATING.......2486
ERROR CODE [D5ZHL6].......2488
START SWITCH C (IGN "C") INPUT FAILURE.......2488
ERROR CODE [DAF3KK].......2490
SW POWER SUPPLY (FOR OPERATION) = ON AND NSW POWER SUPPLY (FOR MEMORY) = OFF.......2490
ERROR CODE [DAF5KP].......2492
5-V POWER SUPPLY OUTPUT FAILURE.......2492
ERROR CODE [DAF6KP].......2494
24-V POWER SUPPLY OUTPUT FAILURE.......2494
ERROR CODE [DAFBKM].......2496
WRONG INFORMATION ON MODEL SELECTION.......2496
ERROR CODE [DAFSKQ].......2497
WRONG INFORMATION ON METER DISPLAY SELECTION.......2497
ERROR CODE [DAQSKR].......2498
S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND TRANSMISSION CONTROLLER).......2498
ERROR CODE [DB2SKR].......2500
S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND ENGINE CONTROLLER.......2500
ERROR CODE [DA80L4].......2502
AUTO GREASE INPUT FAILURE.......2502
ERROR CODE [DBQSKR].......2504
S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER.......2504
ERROR CODE [DD15LD].......2506
MONITOR PANEL MODE SELECTOR SWITCH 1 (PANEL SW1) INPUT ERROR.......2506
ERROR CODE [DD16LD].......2508
MONITOR PANEL MODE SELECTOR SWITCH 1 (PANEL SW2) INPUT ERROR.......2508
ERROR CODE [DD17LD].......2510
MONITOR PANEL MODE SELECTOR SWITCH 2 (PANEL SW3) INPUT ERROR.......2510
ERROR CODE [DD18LD].......2512
MONITOR PANEL MODE SELECTOR SWITCH 2 (PANEL SW4) INPUT ERROR.......2512
ERROR CODE [DD1CLD].......2514
SUB-TOTAL SWITCH FAILURE.......2514
ERROR CODE [DGE2KX].......2516
ENGINE COOLANT TEMPERATURE SENSOR SYSTEM FAILURE.......2516
ERROR CODE [DDK6KM].......2518
CAUTION: FNR (FORWARD-REVERSE) LEVER SWITCH IS IN N (NEUTRAL).......2518
ERROR CODE [DDS5L6].......2519
DECREASED STEERING OIL PRESSURE.......2519
ERROR CODE [DDY0LD].......2521
CANCEL SWITCH FAILURE.......2521
ERROR CODE [DGH2KX].......2523
HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM FAILURE.......2523
ERROR CODE [DGT1KX].......2525
TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM FAILURE.......2525
ERROR CODE [DHE4L6].......2527
ENGINE OIL PRESSURE SENSOR SYSTEM FAILURE.......2527
ERROR CODE [DHPCKX].......2529
BOTTOM PRESSURE SENSOR FAILURE.......2529
ERROR CODE [DHPDKX].......2531
HEAD PRESSURE SENSOR FAILURE.......2531
ERROR CODE [DKA0KX].......2533
BOOM ANGLE SENSOR FAILURE.......2533
ERROR CODE [DV00KB].......2535
SHORT-CIRCUITED ALARM BUZZER OUTPUT SYSTEM.......2535
ERROR CODE [DY30ME].......2537
THE EMERGENCY STEERING REMAINS ACTUATED FOR MORE THAN ONE MINUTE.......2537
ACTION CODE [MON-1].......2539
THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT UP WHEN THE PARKING BRAKE SWITCH IS TURNED ON.......2539
ACTION CODE [MON-2].......2541
CIRCUIT DIAGNOSTIC PROCEDURES FOR ERROR CODE.......2541
ACTION CODE [MON-3].......2543
THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (REAR C.........2543
ACTION CODE [MON-4].......2545
THE AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT ON.......2545
ACTION CODE [MON-5].......2547
THE ENGINE HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON.......2547
ACTION CODE [MON-6].......2549
THE ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT ON.......2549
ACTION CODE [MON-7].......2551
THE ENGINE COOLANT TEMPERATURE CAUTION LAMP DOES NOT LIGHT.......2551
ACTION CODE [MON-8].......2553
THE RADIATOR COOLANT VOLUME CAUTION LAMP DOES NOT LIGHT ON.......2553
ACTION CODE [MON-9].......2555
THE HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT.......2555
ACTION CODE [MON-10].......2557
THE TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON.......2557
ACTION CODE [MON-11].......2559
THE STEERING HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON.......2559
ACTION CODE [MON-12].......2561
INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW1).......2561
ACTION CODE [MON-13].......2563
INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW2).......2563
ACTION CODE [MON-14].......2565
INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW3).......2565
ACTION CODE [MON-15].......2567
INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW4).......2567
ACTION CODE [MON-16].......2569
DEFECTIVE SUBTOTAL SWITCH.......2569
ACTION CODE [MON-17].......2571
DEFECTIVE CANCEL SWITCH.......2571
ACTION CODE [MON-18].......2573
DEFECTIVE BOTTOM PRESSURE SENSOR (SHORT FAULT).......2573
ACTION CODE [MON-19].......2575
DEFECTIVE HEAD SENSOR.......2575
ACTION CODE [MON-20].......2577
THE ALARM BUZZER DOES NOT SOUND OR STOP.......2577
TROUBLESHOOTING OF CHASSIS ELECTRICAL SYSTEM (E MODE).......2579
CONNECTOR TYPES AND INSTALLATION LOCATIONS.......2580
CONNECTOR LAYOUT DRAWING.......2587
ELECTRICAL SYSTEM DIAGRAM.......2593
ACTION CODE: [E-1].......2595
BUCKET POSITIONER, BOOM KICK-OUT, AND FLOAT DO NOT FUNCTION.......2595
ACTION CODE [E-2].......2597
BOOM KICK-OUT DOES NOT FUNCTION OR CANNOT BE RELEASED.......2597
ACTION CODE: [E-3].......2599
BUCKET LEVER DOES NOT FUNCTION OR CANNOT BE RELEASED.......2599
ACTION CODE: [E-4].......2601
BOOM FLOAT DOES NOT FUNCTION OR CANNOT BE CANCLED.......2601
ACTION CODE: [E-5A].......2603
THE FRONT WIPER DOES NOT FUNCTION.......2603
ACTION CODE: [E-5B].......2606
THE REAR WIPER DOES NOT FUNCTION.......2606
ACTION CODE: [E-5C].......2608
THE SIDE WIPER DOES NOT FUNCTION.......2608
ACTION CODE: [E-6].......2610
THE WINDOW WASHER DOES NOT FUNCTION.......2610
ACTION CODE: [E-7A].......2612
THE HEADLAMP (LO BEAM) DOES NOT FUNCTION.......2612
ACTION CODE: [E-7B].......2614
THE HEADLAMP (HI BEAM) DOES NOT FUNCTION.......2614
ACTION CODE: [E-7C].......2616
CLEARANCE LAMPS DO NOT FUNCTION.......2616
ACTION CODE: [E-7D].......2618
TURN SIGNAL DOES NOT FUNCTION.......2618
ACTION CODE: [E-8].......2621
HORN DOES NOT SOUND.......2621
CODE: [E-9].......2622
AIR CONDITIONER SYSTEM DOES NOT WORK.......2622
CODE: (E-9).......2625
AIR DOES NOT FLOW FROM SYSTEM AND CANNOT BE ADJUSTED.......2625
30 DISASSEMBLY AND ASSEMBLY.......2629
METHOD OF USING MANUAL.......2633
PRECAUTIONS WHEN CARRYING OUT OPERATION.......2634
FUEL SUPPLY PUMP ASSEMBLY.......2637
SPECIAL TOOLS.......2637
REMOVAL.......2637
INSTALLATION.......2640
SCHEMATIC DRAWINGS OF SPECIAL TOOLS.......2643
A1 Remover.......2643
A1 Block.......2643
A1 Bolt.......2644
NOZZLE HOLDER ASSEMBLY.......2645
REMOVAL.......2645
INSTALLATION.......2648
CYLINDER HEAD ASSEMBLY.......2650
SPECIAL TOOL.......2650
REMOVAL.......2650
INSTALLATION.......2657
RADIATOR ASSEMBLY.......2660
REMOVAL.......2660
INSTALLATION.......2662
AIR AFTERCOOLER ASSEMBLY.......2663
REMOVAL.......2663
INSTALLATION.......2663
COOLING FAN DRIVE MOTOR.......2664
REMOVAL.......2664
INSTALLATION.......2665
ENGINE ASSEMBLY.......2666
REMOVAL.......2666
INSTALLATION.......2672
STEERING, SWITCH, COOLING FAN PUMPS.......2674
REMOVAL.......2674
INSTALLATION.......2675
TORQUE CONVERTER CHARGE, WORK EQUIPMENT AND PPC PUMP ASSEMBLY.......2676
REMOVAL.......2676
INSTALLATION.......2676
TORQUE CONVERTER, TRANSMISSION ASSEMBLY.......2677
REMOVAL.......2677
INSTALLATION.......2682
TORQUE CONVERTER ASSEMBLY (standard).......2683
SPECIAL TOOLS.......2683
DISASSEMBLY.......2683
ASSEMBLY.......2685
TORQUE CONVERTER ASSEMBLY (lock-up).......2688
SPECIAL TOOLS.......2688
DISASSEMBLY.......2688
ASSEMBLY.......2691
TRANSMISSION ASSEMBLY.......2696
SPECIAL TOOLS.......2696
DISASSEMBLY.......2696
ASSEMBLY.......2704
SCHEMATICS OF SPECIAL TOOLS.......2714
C1 Bracket.......2714
C6, C7 Pushing tools.......2714
C7 Spacer.......2715
C11 Lifting tool.......2715
C11 Lifting tool.......2716
TRANSMISSION CLUTCH PACK ASSEMBLY.......2717
SPECIAL TOOLS.......2717
DISASSEMBLY.......2717
Disassembly of forward-reverse clutch packs.......2717
Forward clutch.......2717
Reverse clutch.......2719
Disassembly of 1st 4th speed clutch packs.......2720
1st speed clutch.......2720
4th speed clutch.......2721
Disassembly of 2nd 3rd clutch packs.......2722
3rd clutch.......2722
2nd speed clutch.......2724
Assembly of forward-reverse clutch packs.......2725
Reverse clutch.......2725
Forward clutch.......2727
Assembly of 1st 4th clutch packs.......2729
4th-speed clutch.......2729
1st-speed clutch.......2731
Assembly of 2nd 3rd clutch packs.......2733
2nd-speed clutch.......2733
3rd-speed clutch.......2735
SCHEMATIC DIAGRAM OF SPECIAL TOOL.......2739
C2 Push tool.......2739
PARKING BRAKE ASSEMBLY.......2740
SPECIAL TOOLS.......2740
DISASSEMBLY.......2740
ASSEMBLY.......2743
SCHEMATIC DRAWING OF SPECIAL TOOLS.......2749
C4, C5 Push tool.......2749
C5 Spacer.......2749
C8 Push tool.......2750
C9 Push tool.......2750
C10 Push tool.......2751
C13 Bracket.......2751
FRONT AXLE ASSEMBLY.......2752
DISASSEMBLY.......2752
ASSEMBLY.......2754
REAR AXLE ASSEMBLY.......2755
REMOVAL.......2755
INSTALLATION.......2758
AXLE HOUSING ASSEMBLY.......2760
SPECIAL TOOLS.......2760
DISASSEMBLY.......2760
ASSEMBLY.......2764
SCHEMATIC DRAWING OF SPECIAL TOOLS.......2770
D7 Pushing tool.......2770
D7 Spacer.......2770
D7 Pushing tool.......2771
D9 Support.......2771
D9 Support.......2772
DIFFERENTIAL ASSEMBLY.......2773
SPECIAL TOOLS.......2773
DISASSEMBLY.......2773
ASSEMBLY.......2779
SCHEMATIC DRAWING OF SPECIAL TOOLS.......2791
D1 Plate.......2791
D2, D3 Push tool.......2791
D3 Spacer.......2792
D4 Push tool.......2792
D5 Push tool.......2793
CENTER HINGE PIN.......2794
SPECIAL TOOLS.......2794
REMOVAL.......2794
INSTALLATION.......2800
VALVE ASSEMBLY.......2804
REMOVAL.......2804
INSTALLATION.......2804
TRAVEL DAMPER ASSEMBLY.......2805
REMOVAL.......2805
INSTALLATION.......2805
PARKING BRAKE DISC.......2806
SPECIAL TOOLS.......2806
REMOVAL.......2806
INSTALLATION.......2808
SCHEMATIC DRAWING OF SPECIAL TOOLS.......2809
C13 Bracket.......2809
HYDRAULIC TANK.......2810
REMOVAL.......2810
INSTALLATION.......2811
WORK EQUIPMENT VALVE ASSEMBLY.......2812
REMOVAL.......2812
INSTALLATION.......2813
HYDRAULIC CYLINDER ASSEMBLY.......2814
SPECIAL TOOLS.......2814
DISASSEMBLY.......2814
ASSEMBLY.......2818
WORK EQUIPMENT ASSEMBLY.......2824
REMOVAL.......2824
INSTALLATION.......2827
COUNTERWEIGHT.......2829
REMOVAL.......2829
INSTALLATION.......2830
FUEL TANK ASSEMBLY.......2831
REMOVAL.......2831
INSTALLATION.......2832
CAB ASSEMBLY.......2833
REMOVAL.......2833
INSTALLATION.......2836
CAB, FLOOR FRAME ASSEMBLY.......2837
REMOVAL.......2837
INSTALLATION.......2841
AIR CONDITIONER UNIT ASSEMBLY.......2842
REMOVAL.......2842
INSTALLATION.......2845
AIR CONDITIONER COMPRESSOR ASSEMBLY.......2846
SPECIAL TOOLS.......2846
REMOVAL.......2846
INSTALLATION.......2847
ECSS AND LOAD METER SUPPLEMENT.......2864
COVER.......2864
CONTENTS.......2865
ECSS VALVE (OP).......2866
MACHINE MONITOR.......2868
LOAD METER FUNCTION (OP).......2868
AMP070-20 [CN-L51].......2877
AMP070-12P [CN-L57].......2879
TRANSMISSION CONTROLLER.......2881
INPUT AND OUTPUT SIGNALS.......2882
TESTING AND ADJUSTING LOAD METER.......2883
TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM.......2887
CONNECTOR TYPES AND INSTALLATION POSITIONS.......2887
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE).......2895
H-30 ECSS DOES NOT WORK, AND THERE IS PITCHING AND BOUNCING.......2895
SEBM009904 - Log Loader WA450-3LL Shop Manual.......2896
COVER.......2896
CONTENTS.......2897
01 GENERAL.......2923
GENERAL ASSEMBLY DRAWING.......2924
SPECIFICATIONS.......2926
WEIGHT TABLE.......2929
LIST OF LUBRICANT AND WATER.......2931
10 STRUCTURE AND FUNCTION.......2933
POWER TRAIN.......2934
POWER TRAIN SYSTEM .......2935
TORQUE CONVERTER, TRANSMISSION PIPING.......2937
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM.......2938
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM.......2939
TORQUE CONVERTER.......2940
TORQUE CONVERTER OIL FILTER.......2943
TRANSMISSION.......2944
TRANSMISSION CONTROL VALVE.......2954
TRANSMISSION SOLENOID VALVE.......2976
PILOT OIL FILTER.......2977
DRIVE SHAFT.......2978
AXLE.......2979
DIFFERENTIAL.......2981
FINAL DRIVE.......2985
AXLE MOUNT,CENTER HINGE PIN.......2986
STEERING PIPING.......2988
STEERING COLUMN.......2989
STEERING VALVE.......2990
ORBIT-ROLL VALVE.......3004
STOP VALVE.......3008
EMERGENCY STEERING PUMP (OPTION).......3009
DIVERTER VALVE (OPTION).......3010
BRAKE PIPING.......3013
BRAKE CIRCUIT DIAGRAM.......3014
BRAKE VALVE.......3016
CHARGE VALVE.......3021
ACCUMULATOR (FOR BRAKE).......3025
SLACK ADJUSTER.......3026
BRAKE COOLING PIPING.......3029
BRAKE COOLING CIRCUIT DIAGRAM.......3030
BRAKE.......3031
BRAKE COOLING.......3033
PARKING BRAKE CONTROL.......3034
PARKING BRAKE.......3035
PARKING BRAKE SOLENOID VALVE.......3036
PARKING BRAKE VALVE.......3037
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE.......3038
HYDRAULIC PIPING.......3039
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM.......3040
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.......3042
WORK EQUIPMENT LEVER LINKAGE.......3043
HYDRAULIC TANK.......3044
PPC VALVE.......3046
PPC RELIEF VALVE.......3051
ACCUMULATOR (FOR PPC VALVE).......3052
CUT-OFF VALVE.......3053
MAIN CONTROL VALVE.......3056
WORK EQUIPMENT LINKAGE.......3070
LOG GRAPPLE.......3072
FORK POSITIONER AND LIFT ARM KICK-OUT.......3073
CAB (OPTION).......3079
AIR CONDITIONER (OPTION).......3080
ELECTRIC CIRCUIT DIAGRAM.......3081
MACHINE MONITOR SYSTEM.......3083
MAIN MONITOR.......3084
MAINTENANCE MONITOR.......3089
E.C.S.S........3091
SENSORS.......3095
ENGINE STARTING CIRCUIT.......3100
ENGINE STOP CIRCUIT.......3101
PREHEATING CIRCUIT.......3102
ELECTRIC TRANSMISSION CONTROL.......3103
KICK-DOWN SWICTH.......3106
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM.......3107
TRANSMISSION CUT-OFF SWITCH.......3112
TRANSMISSION CUT-OFF FUNCTION.......3113
ELECTRIC PARKING BRAKE CONTROL.......3115
20 TESTING AND ADJUSTING.......3127
STANDARD VALUE TABLE FOR ENGINE.......3128
STANDARD VALUE TABLE FOR CHASSIS.......3129
STANDARD VALUE TABLE FOR ELECTRICAL PARTS.......3132
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING.......3135
MEASURING ENGINE SPEED.......3136
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE).......3137
ADJUSTING VALVE CLEARANCE.......3138
MEASURING EXHAUST COLOR.......3139
MEASURING EXHAUST GAS TEMPERATURE.......3140
MEASURING BLOW-BY PRESSURE.......3141
MEASURING COMPRESSION PRESSURE.......3142
