Compositionofshopmanual
ThecontentsofthisshopmanualareshowntogetherwithFormNo.inalist.
Note1:Alwayskeepthelatestversionofthismanualinaccordancewiththislistandutilizeaccordingly.
ThemarksshowntotherightofFormNo.denotethefollowing:
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Note3:Tofilethisshopmanualinthespecialbinderformanagement,handleitasfollows:
•PlaceadivideronthetopofeachsectioninthefileaftermatchingtheTubNo.withNo.indicated nexttoeachSectionNameshowninthetablebelow:
•Fileoverviewandothermaterialsinsectionsintheordershownbelowandutilizethemaccordingly.
SectionTitleFormNumber
ShopManualVEBM440102
00Indexandforeword
IndexSEN00123-15
ForewordandgeneralinformationSEN00124-04
01Specification
SpecificationandtechnicaldataSEN00125-03
10Structure,functionandmaintenancestandard
EngineandcoolingsystemSEN01028-03
PowertrainSEN01029-02
SteeringsystemSEN01030-03
BrakesystemSEN01031-04
UndercarriageandframeSEN01032-01
Hydraulicsystem,Part1SEN01033-04
Hydraulicsystem,Part2SEN01034-02
WorkequipmentSEN01035-02
CabanditsattachmentsSEN01036-04
Electricalsystem,Part1SEN01037-02
Electricalsystem,Part2SEN01038-03
Electricalsystem,Part3SEN01039-03
CentralLubricationSystem(CLS)CLS10-01
20Standardvaluetable
StandardservicevaluetableSEN01244-01
30Testingandadjusting
Testingandadjusting,Part1SEN01245-02
Testingandadjusting,Part2SEN01246-03
Testingandadjusting,Part3SEN01247-04
40Troubleshooting
FailurecodetableandfuselocationsSEN03961-04
GeneralinformationontroubleshootingSEN01261-02
Troubleshootingbyfailurecode(Displayofcode),Part1SEN01248-04
Troubleshootingbyfailurecode(Displayofcode),Part2SEN01249-03
Troubleshootingbyfailurecode(Displayofcode),Part3SEN01250-05
Troubleshootingbyfailurecode(Displayofcode),Part4SEN01251-02
Troubleshootingbyfailurecode(Displayofcode),Part5SEN01252-03
Troubleshootingbyfailurecode(Displayofcode),Part6SEN01253-05
Troubleshootingbyfailurecode(Displayofcode),Part7SEN01254-01
Troubleshootingbyfailurecode(Displayofcode),Part8SEN01255-03
Troubleshootingbyfailurecode(Displayofcode),Part9SEN01256-02
Troubleshootingbyfailurecode(Displayofcode),Part10SEN01257-02
Troubleshootingofelectricalsystem(E-mode)SEN01258-03
Troubleshootingofhydraulicandmechanicalsystem(H-mode)SEN01259-03
Troubleshootingofengine(S-mode)SEN01260-02
TroubleshootingofCentralLubricationSystem(CLS)CLS40-01
50Disassemblyandassembly
GeneralinformationondisassemblyandassemblySEN01451-03
EngineandcoolingsystemSEN01452-03 PowertrainSEN01453-03 SteeringsystemSEN01454-02 BrakesystemSEN01455-03
UndercarriageandframeSEN01456-01
HydraulicsystemSEN01457-01
WorkequipmentSEN01458-01
CabanditsattachmentsSEN01459-03
ElectricalsystemSEN01460-01
90Diagramsanddrawings
HydraulicdiagramsanddrawingsSEN00126-01
ElectricaldiagramsanddrawingsSEN00127-04
Tableofcontents
CentralLubricationSystem(CLS)CLS10-01 Auto-greasepump...................................................................................................................2 Changingthelubricationintervaltimes....................................................................................3
20Standardvaluetable
30Testingandadjusting
Testingandadjusting,Part1SEN01245-02
Toolsfortesting,adjusting,andtroubleshooting......................................................................3
Releasingresidualpressureinfuelsystem.............................................................................22
Testingfuelpressure................................................................................................................23
Testingfueldelivery,returnandleakamount..........................................................................25
Bleedingairfromfuelcircuit....................................................................................................28
Testingleakageinfuelsystem.................................................................................................29 Handlingreducedcylindermodeoperation.............................................................................30
Handlingno-injectioncrankingoperation.................................................................................30
Handlingcontrollervoltagecircuit............................................................................................31
Testingdirectionallever...........................................................................................................35
Testingandadjustingpowertrainoilpressure.........................................................................36
Procedureforflushingtorqueconverterandtransmissionhydrauliccircuit............................51
Methodofmovingmachinewhentransmissionvalveisbroken..............................................52
Testingandadjustingsteeringstopvalve................................................................................54
Testingandadjustingsteeringwheel.......................................................................................56
Testingandadjustingsteeringoilpressure..............................................................................58
Bleedingairfromsteeringcircuit.............................................................................................61
Testingandadjusting,Part2SEN01246-03
Testinghydraulicdrivefan.......................................................................................................3
Bleedingairfromhydraulicdrivefancircuit.............................................................................5
Testingbrakepedal..................................................................................................................7
Testingbrakeperformance......................................................................................................8
Testingandadjustingaccumulatorchargepressure...............................................................9
Testingwheelbrakeoilpressure.............................................................................................10
Testingwearofwheelbrakedisc.............................................................................................12
Bleedingairfromwheelbrakecircuit.......................................................................................13
Releasingresidualpressureinbrakeaccumulatorcircuit.......................................................14
Testingparkingbrakeperformance.........................................................................................15
Testingparkingbrakeoilpressure...........................................................................................16
Testingwearofparkingbrakedisc..........................................................................................18
Methodofreleasingparkingbrakemanually...........................................................................19
Testingandadjustingworkequipmentcontrollever................................................................20
TestingandadjustingworkequipmentPPCoilpressure........................................................21
Testingandadjustingworkequipmentoilpressure.................................................................24
Bleedingairfromworkequipmentcircuit.................................................................................28
Releasingresidualpressureinworkequipmentcircuit...........................................................29
ProcedurefortestingofnitrogengaspressureandchargingofnitrogengasofECSS (ElectronicallyControlledSuspensionSystem)accumulator...........................................30
Testingandadjustingbucketpositioner...................................................................................36
Testingandadjustingboomkick-out.......................................................................................38
Checkingproximityswitchoperationpilotlamp.......................................................................39
Procedurefortestingdiodes....................................................................................................40
Preparationworkfortroubleshootingforelectricsystem.........................................................41
HowtostartoperationofKOMTRAXterminal.........................................................................46
LampdisplayofKOMTRAXterminal.......................................................................................51
Testingandadjusting,Part3SEN01247-04
Adjustingreplaced,reassembledoraddedsensor,controller,etc.withmachinemonitor......3
Specialfunctionsofmachinemonitor(EMMS)........................................................................5
Pm-clinicinspectiontable........................................................................................................74
40Troubleshooting
FailurecodetableandfuselocationsSEN03961-04
Failurecodetable....................................................................................................................2
Fuselocations.........................................................................................................................12
GeneralinformationontroubleshootingSEN01261-02
Pointstorememberwhentroubleshooting..............................................................................2
Sequenceofeventsintroubleshooting...................................................................................3
Testingbeforetroubleshooting................................................................................................4
Classificationandproceduresoftroubleshooting....................................................................5
Informationcontainedintroubleshootingtable........................................................................8
Connectiontableforconnectorpinnumbers...........................................................................10
T-branchboxandT-branchadaptertable.............................................................................46
Troubleshootingbyfailurecode(Displayofcode),Part1SEN01248-04
Failurecode[1500L0](TORQFLOWtransmission:Doublemeshing)......................................3
Failurecode[15SAL1](ECMVFclutch:WhencommandcurrentisOFF,fillsignalisON).....4
Failurecode[15SALH](ECMVFclutch:WhencommandcurrentisON,fillsignalisOFF)....6
Failurecode[15SBL1](ECMVRclutch:WhencommandcurrentisOFF,fillsignalisON).....8
Failurecode[15SBLH](ECMVRclutch:WhencommandcurrentisON,fillsignalisOFF)....10
Failurecode[15SEL1](ECMV1stclutch:WhencommandcurrentisOFF,fillsignalisON)...12
Failurecode[15SELH](ECMV1stclutch:WhencommandcurrentisON,fillsignalisOFF)..14
Failurecode[15SFL1](ECMV2ndclutch:WhencommandcurrentisOFF,fillsignalisON)..16
Failurecode[15SFLH](ECMV2ndclutch:WhencommandcurrentisON,fillsignalisOFF).18
Failurecode[15SGL1](ECMV3rdclutch:WhencommandcurrentisOFF,fillsignalisON)..20
Failurecode[15SGLH](ECMV3rdclutch:WhencommandcurrentisON,fillsignalisOFF).22
Failurecode[15SHL1](ECMV4thclutch:WhencommandcurrentisOFF,fillsignalisON)..24
Failurecode[15SHLH](ECMV4thclutch:WhencommandcurrentisON,fillsignalisOFF).26
Failurecode[2F00MA](Parkingbrake:Malfunction)................................................................28
Failurecode[2G43ZG](Accumulator:Lowoilpressure)..........................................................30
Failurecode[44K0L4](Bucketpositioner:ON/OFFsignalsdisagree).....................................32
Troubleshootingbyfailurecode(Displayofcode),Part2SEN01249-03
Failurecode[AA1ANX](Aircleaner:Clogging).......................................................................4
Failurecode[AB00L6](Alternator:Signaldisagreeswithoperatingstateofengine).............6
Failurecode[AB00MA](Alternator:Malfunction)....................................................................8
Failurecode[B@BAZG](Rotationderatingbylowengineoilpressure).................................10
Failurecode[B@BAZK](Engineoil:Lowlevel)......................................................................11
Failurecode[B@BCNS](Coolant:Overheating).....................................................................12
Failurecode[B@BCZK](Coolant:Lowlevel)..........................................................................14
Failurecode[B@BEBF](Waterinfuelerror)..........................................................................16
Failurecode[B@C7NS](Brakeoil:Overheating)...................................................................18
Failurecode[b@CENS](Torqueconverteroil:Overheating)..................................................20
Failurecode[B@CENS](Torqueconverteroil:Overheating).................................................22
Failurecode[B@HANS](Hydraulicoil:Overheating).............................................................24
Failurecode[CA111](Abnormalityinenginecontroller)..........................................................26
Failurecode[CA115](EngineNeorBkupspeedsensorerror)..............................................27
Failurecode[CA122](Chargepressuresensorhigherror).....................................................28
Failurecode[CA123](Chargepressuresensorlowerror)......................................................30
Failurecode[CA131](Throttlesensorhigherror)...................................................................32
Failurecode[CA132](Throttlesensorlowerror).....................................................................34
Failurecode[CA144](Coolantsensorhigherror)...................................................................36
Failurecode[CA145](Coolantsensorlowerror)....................................................................38
Failurecode[CA153](Chargetemperaturesensorhigherror)...............................................40
Failurecode[CA154](Chargetemperaturesensorlowerror).................................................42
Failurecode[CA155](Deratingofspeedbyabnormallyhighchargetemperature)................44
Failurecode[CA187](Sensorpowersupply2lowerror)........................................................46
Failurecode[CA221](Atmosphericpressuresensorhigherror)............................................48
Failurecode[CA222](Atmosphericsensorlowerror).............................................................50
Failurecode[CA227](Sensorpowersupply2higherror).......................................................52
Failurecode[CA234](Engineoverspeed)...............................................................................53
Failurecode[CA238](Nespeedsensorpowersupplyerror)..................................................54
Troubleshootingbyfailurecode(Displayofcode),Part3SEN01250-05
Failurecode[CA271](IMV/PCV1Shortcircuit).......................................................................3
Failurecode[CA272](IMV/PCV1Disconnection)...................................................................4
Failurecode[CA322](Injector#1open/shorterror)................................................................6
Failurecode[CA323](Injector#5open/shorterror)................................................................8
Failurecode[CA324](Injector#3open/shorterror)................................................................10
Failurecode[CA325](Injector#6open/shorterror)................................................................12
Failurecode[CA331](Injector#2open/shorterror)................................................................14
Failurecode[CA332](Injector#4open/shorterror)................................................................16
Failurecode[CA342](Calibrationcodeinconsistency)...........................................................18
Failurecode[CA351](Injectorsdrivecircuiterror)..................................................................20
Failurecode[CA352](Sensorpowersupply1lowerror)........................................................22
Failurecode[CA386](Sensorpowersupply1higherror).......................................................24
Failurecode[CA428](Abnormallyhighlevelinwatersensor)................................................25
Failurecode[CA429](Abnormallylowlevelinwatersensor).................................................26
Failurecode[CA431](Idlevalidationswitcherror)..................................................................27
Failurecode[CA432](Idlevalidationactionerror)..................................................................30
Failurecode[CA435](Engineoilpressureswitcherror).........................................................32
Failurecode[CA441](Batteryvoltagelowerror).....................................................................33
Failurecode[CA442](Batteryvoltagehigherror)...................................................................36
Failurecode[CA449]Commonrailpressurehigherror2.......................................................38
Failurecode[CA451](Commonrailpressuresensorhigherror)............................................40
Failurecode[CA452](Commonrailpressuresensorlowerror).............................................42
Failurecode[CA488](Deratingoftorquebyabnormallyhighchargetemperature)...............44
Failurecode[CA553](Commonrailpressurehigherror1).....................................................45
Failurecode[CA559](Supplypumppressureverylowerror).................................................46
Failurecode[CA689](EngineNespeedsensorerror)............................................................48
Failurecode[CA731](EngineBkupspeedsensorphaseerror).............................................50
Failurecode[CA757](Allcontinuousdatalosterror)..............................................................51
Failurecode[CA778](EngineBkupspeedsensorerror)........................................................54
Failurecode[CA1633](KOMNETdatalinktimeouterror).......................................................56
Failurecode[CA2185](Throttlesensorpowersupplyvoltagehigherror)..............................58
Failurecode[CA2186](Throttlesensorpowersupplyvoltagelowerror)................................59
Troubleshootingbyfailurecode(Displayofcode),Part4SEN01251-02
Failurecode[CA2249](Supplypumppressureverylowerror2)............................................3
Failurecode[CA2311](AbnormalityinIMVsolenoid).............................................................4
Failurecode[CA2555](Intakeheaterrelaydisconnectionerror)............................................6
Failurecode[CA2556](Intakeheaterrelayshortcircuiterror)................................................8
Failurecode[D150KA](Emergencysteeringrelay:Disconnection)........................................10
Failurecode[D150KB](Emergencysteeringrelay:Shortcircuit)...........................................12
Failurecode[D150KY](Emergencysteeringrelay:Shortcircuitwithpowersupplyline).......14
Failurecode[D160KA](Backuplamprelay:Disconnection)...................................................16
Failurecode[D160KB](Backuplamprelay:Shortcircuit)......................................................18
Failurecode[D191KA](Joysticksteeringneutralsafetyrelay:Disconnection)......................20
Failurecode[D191KB](Joysticksteeringneutralsafetyrelay:Shortcircuit)..........................22
Failurecode[D191KY](Joysticksteeringneutralsafetyrelay:Shortcircuit withpowersupplyline).......................................................................................24
Failurecode[D192KA](ECSSsolenoid:Disconnection)........................................................26
Failurecode[D192KB](ECSSsolenoid:Shortcircuit)............................................................27
Failurecode[D192KY](ECSSsolenoid:Shortcircuitwithpowersupplyline)........................28
Failurecode[D193KA](Joysticksteeringsolenoidcutrelay:Disconnection).........................30
Failurecode[D193KB](Joysticksteeringsolenoidcutrelay:Shortcircuit)............................32
Failurecode[D193KY](Joysticksteeringsolenoidcutrelay:Shortcircuit withpowersupplyline).......................................................................................34
Failurecode[D5ZHKA](TerminalCsignal:Disconnection)....................................................37
Failurecode[D5ZHKB](TerminalCsignal:Shortcircuit)........................................................41
Failurecode[D5ZHKZ](TerminalCsignal:Disconnectionorshortcircuit).............................44
Failurecode[D5ZHL6](TerminalCsignal:Signaldoesnotmatchenginerunning orstoppedstate)................................................................................................49
Failurecode[DA80L4](Autogreasecontroller:ON/OFFsignalsdisagree)............................52
Failurecode[DAF3KK](Machinemonitor:Lowsourcevoltage(input)...................................54
Failurecode[DAF5KP](Machinemonitor:Lowoutputvoltage)..............................................56
Failurecode[DAFRKR](CANcommunicationwithmachinemonitor: Defectivecommunication(Abnormalityintargetcomponentsystem)...............60
Troubleshootingbyfailurecode(Displayofcode),Part5SEN01252-03
Failurecode[DAQ0KK](Transmissioncontroller:Lowsourcevoltage)..................................4
Failurecode[DAQ0KT](Transmissioncontroller:Abnormalityincontroller)..........................6
Failurecode[DAQ2KK](Transmissioncontrollerloadpowersupplyline: Lowsourcevoltage(input).................................................................................7
Failurecode[DAQ9KQ](Transmissioncontrollermodelselection: Disagreementofmodelselectionsignals).........................................................9
Failurecode[DAQRKR](CANcommunicationwithtransmissioncontroller: Defectivecommunication(Abnormalityintargetcomponentsystem)...............10
Failurecode[DAQRMA](Transmissioncontrolleroptionsetting:Malfunction).......................13
Failurecode[DB2RKR](CANcommunicationwithenginecontroller:Defective communication(Abnormalityintargetcomponentsystem)...............................14
Failurecode[DB90KK]Workequipmentcontroller:Lowsourcevoltage(input).....................16
Failurecode[DB90KT]Workequipmentcontroller:Abnormalityincontroller.........................18
Failurecode[DB92KK]Workequipmentcontrollerloadpowersupplyline: Lowsourcevoltage(input).................................................................................19
Failurecode[DB95KX]Workequipmentcontrollerpowersupplyoutput: Outofinputsignalrange....................................................................................21
Failurecode[DB99KQ](Workequipmentcontrollermodelselection: Disagreementinmodelselectionsignals).........................................................24
Failurecode[DB9RKR]CANcommunicationwithworkequipmentcontroller:Defective communication(Abnormalityintargetcomponentsystem)...............................25
Failurecode[DB9RMA](Workequipmentcontrolleroptionsetting:Malfunction)...................27
Failurecode[DB9RMC](CANcommunicationwithtransmissioncontroller, enginecontrollerandmachinemonitor:Defectiveoperation)............................28
Failurecode[DD15LD]tswitch(Panelswitch1):Switchiskeptpressedforlongtime..........32
Failurecode[DD16LD]Uswitch(Panelswitch2):Switchiskeptpressedforlongtime........34
Failurecode[DD17LD]<switch(Panelswitch3):Switchiskeptpressedforlongtime.........36
Failurecode[DD18LD]>switch(Panelswitch4):Switchiskeptpressedforlongtime.........38
Failurecode[DD1ALD]Remotepositionerraise/lowersetswitch(raise): Switchiskeptpressedforlongtime...................................................................40
Failurecode[DD1BLD]Remotepositionerraise/lowersetswitch(lower): Switchiskeptpressedforlongtime...................................................................42
Failurecode[DD1CLD]Loadmetersubtotalswitch:Switchiskeptpressedforlongtime.....44
Failurecode[DD1FLD]Loadmetermodeselectorswitch(A/B): Switchiskeptpressedforlongtime...................................................................46
Failurecode[DD1GLD]Loadmetermodeselectorswitch(+/–): Switchiskeptpressedforlongtime...................................................................48
Failurecode[DD1HLD](Loadmeterdisplayselectorswitch: Switchiskeptpressedforlongtime).................................................................50
Failurecode[DD1NLD](Fanreverseswitch:Switchiskeptpressedforlongtime)...............52
Failurecode[DD1NL4](Fanautomaticreverseswitch:Switchiskeptpressedforlongtime)54
Failurecode[DDB6L4](Parkingbrakeswitch(Neutralizer):ON/OFFsignalsdisagree)........56
Troubleshootingbyfailurecode(Displayofcode),Part6SEN01253-05
Failurecode[DDE5MA](Emergencysteeringdriveswitch:Malfunction)................................4
Failurecode[DDK3KA](RightFNRswitch:Disconnection)....................................................6
Failurecode[DDK4KA](JoysticksteeringFNRswitch:Disconnection)..................................9
Failurecode[DDK5L4](Joysticksteeringshift-up/downswitch:ON/OFFsignalsdisagree)...12
Failurecode[DDK6KA](FNRleverswitch:Disconnection).....................................................14
Failurecode[DDK6KB](FNRleverswitch:Shortcircuit)........................................................18
Failurecode[DDS5KA](Steeringpressureswitch:Disconnected)..........................................20
Failurecode[DDS5KB](Steeringpressureswitch:Grounded)...............................................22
Failurecode[DDT0L4](Shiftmodeselectorswitch:ON/OFFsignalsdisagree).....................24
Failurecode[DDT4LD](Transmissioncut-offsetswitch:Switchiskeptpressedforlongtime)26
Failurecode[DDW9LD](Kick-downswitch:Switchiskeptpressedforlongtime)..................28
Failurecode[DDWLLD](Holdswitch:Switchiskeptpressedforlongtime)...........................30
Failurecode[DDY0LD](Loadmetercancelswitch:Switchiskeptpressedforlongtime).....32
Failurecode[DF10KA](Transmissionshiftleverswitch:Disconnected).................................34
Failurecode[DF10KB](Transmissionshiftleverswitch:Shortcircuit)....................................38
Failurecode[DGF1KA](Transmissionoiltemperaturesensor:Disconnected).......................40
Failurecode[DGF1KB](Transmissionoiltemperaturesensor:Shortcircuit).........................42
Failurecode[DGH2KX](Hydraulicoiltemperaturesensor:Outofinputsignalrange)...........44
Failurecode[DGR2KA](Rearbrakeoiltemperaturesensor:Disconnected)..........................46
Failurecode[DGR2KX](Rearbrakeoiltemperaturesensor:Outofinputsignalrange)........48
Failurecode[DGT1KX](Torqueconverteroiltemperaturesensor:Outofinputsignalrange)50
Failurecode[DH21KA](Loaderpumppressuresensor:Disconnection)................................52
Failurecode[DH21KB](Loaderpumppressuresensor:Powersupplylineshort)..................54
Troubleshootingbyfailurecode(Displayofcode),Part7SEN01254-01
Failurecode[DHPCKX](Liftarmcylinderbottompressuresensor:Outofinputsignalrange)4
Failurecode[DHPDKX](Liftarmcylinderheadpressuresensor:Outofinputsignalrange).6
Failurecode[DHT1KX](Transmissioncut-offpressuresensor:Outofinputsignalrange)....8
Failurecode[DHT8KA](Steeringpumppressuresensor:Disconnection)..............................10
Failurecode[DHT8KB](Steeringpumppressuresensor:Shortcircuit).................................12
Failurecode[DK59KA](LiftarmEPCleverpotentiometer(Main):Disconnection).................14
Failurecode[DK59KY](LiftarmEPCleverpotentiometer(Main): Shortcircuitwithpowersupplyline)...................................................................17
Failurecode[DK59L8](LiftarmEPCleverpotentiometer(Main):Analogsignalsdisagree)..20
Failurecode[DK5AKA](LiftarmEPCleverpotentiometer(Sub):Disconnection)..................23
Failurecode[DK5AKY](LiftarmEPCleverpotentiometer(Sub): Shortcircuitwithpowersupplyline)...................................................................26
Failurecode[DK5BKA](BucketEPCleverpotentiometer(Main):Disconnection).................29
Failurecode[DK5BKY](BucketEPCleverpotentiometer(Main): Shortcircuitwithpowersupplyline)...................................................................32
Failurecode[DK5BL8](BucketEPCleverpotentiometer(Main):Analogsignalsdisagree)...35
Failurecode[DK5CKA](BucketEPCleverpotentiometer(Sub):Disconnection)...................38
Failurecode[DK5CKY](BucketEPCleverpotentiometer(Sub): Shortcircuitwithpowersupplyline)...................................................................41
Troubleshootingbyfailurecode(Displayofcode),Part8SEN01255-03
Failurecode[DK5FKA](JoysticksteeringEPCleverpotentiometer(Main):Disconnection)..3
Failurecode[DK5FKY](JoysticksteeringEPCleverpotentiometer(Main): Shortcircuitwithpowersupplyline)...................................................................6
Failurecode[DK5GKA](JoysticksteeringEPCleverpotentiometer(Sub):Disconnection)...8
Failurecode[DK5GKY](JoysticksteeringEPCleverpotentiometer(Sub): Shortcircuitwithpowersupplyline)...................................................................12
Failurecode[DK5FL8](JoysticksteeringEPCleverpotentiometer(Main): Analogsignalsdisagree)....................................................................................14
Failurecode[DKA0KA](Liftarmanglesensor:Disconnection)..............................................18
Failurecode[DKA0KY](Liftarmanglesensor:Shortcircuitwithpowersupplyline)..............20
Failurecode[DKA0L0](Liftarmanglesensor:Dislocationofsensor)....................................22
Failurecode[DLT3KA](Transmissionoutputshaftspeedsensor:Disconnection).................24
Failurecode[DLT3LC](Transmissionoutputshaftspeedsensor:Outofinputsignalrange).26
Failurecode[DT20KB](Transmissioncut-offindicatorlamp:Shortcircuit)............................28
Failurecode[DUM1KB](Remotepositionerraisesetindicatorlamp:Shortcircuit)...............30
Failurecode[DUM2KB](Remotepositionerlowersetindicatorlamp:Shortcircuit)..............32
Failurecode[DV00KB](Alarmbuzzer:Shortcircuit)..............................................................34
Failurecode[DW4PKA](LiftarmraiseEPCsolenoid:Disconnection)...................................36
Failurecode[DW4PKB](LiftarmraiseEPCsolenoid:Shortcircuit).......................................38
Failurecode[DW4PKY](LiftarmraiseEPCsolenoid:Shortcircuitwithpowersupplyline)...40
Failurecode[DW4QKA](LiftarmlowerEPCsolenoid:Disconnection)..................................42
Failurecode[DW4QKB](LiftarmlowerEPCsolenoid:Shortcircuit)......................................43
Failurecode[DW4QKY](LiftarmlowerEPCsolenoid:Shortcircuitwithpowersupplyline).44
Failurecode[DW4RKA](BuckettiltEPCsolenoid:Disconnection)........................................46
Failurecode[DW4RKB](BuckettiltEPCsolenoid:Shortcircuit)............................................47
Failurecode[DW4RKY](BuckettiltEPCsolenoid:Shortcircuitwithpowersupplyline).......48
Troubleshootingbyfailurecode(Displayofcode),Part9SEN01256-02
Failurecode[DW4SKA](BucketdumpEPCsolenoid:Disconnection)...................................3
Failurecode[DW4SKB](BucketdumpEPCsolenoid:Shortcircuit)......................................4
Failurecode[DW4SKY](BucketdumpEPCsolenoid:Shortcircuitwithpowersupplyline)..6
Failurecode[DW7BKA](Fanreversesolenoid:Disconnection).............................................8
Failurecode[DW7BKB](Fanreversesolenoid:Shortcircuit).................................................9
Failurecode[DW7BKY](Fanreversesolenoid:Shortcircuitwithpowersupplyline)............10
Failurecode[DWM1KA](Workequipmentneutrallocksolenoid:Disconnection)..................12
Failurecode[DWM1KB](Workequipmentneutrallocksolenoid:Shortcircuit)......................14
Failurecode[DWM1KY](Workequipmentneutrallocksolenoid: Shortcircuitwithpowersupplyline)...................................................................16
Failurecode[DWN6KA](Liftarmraisemagnetdetentsolenoid:Disconnection)...................18
Failurecode[DWN6KB](Liftarmraisemagnetdetentsolenoid:Shortcircuit).......................20
Failurecode[DWN6KY](Liftarmraisemagnetdetentsolenoid: Shortcircuitwithpowersupplyline)...................................................................22
Failurecode[DWN7KA](Liftarmfloatmagnetdetentsolenoid:Disconnection)....................24
Failurecode[DWN7KB](Liftarmfloatmagnetdetentsolenoid:Shortcircuit)........................26
Failurecode[DWN7KY](Liftarmfloatmagnetdetentsolenoid: Shortcircuitwithpowersupplyline)...................................................................28
Failurecode[DWN8KA](Buckettiltmagnetdetentsolenoid:Disconnection)........................30
Failurecode[DWN8KB](Buckettiltmagnetdetentsolenoid:Shortcircuit)............................32
Failurecode[DWN8KY](Buckettiltmagnetdetentsolenoid:Shortedwiththepowersource)34
Failurecode[DX16KA](FanpumpEPCsolenoid:Disconnection).........................................36
Failurecode[DX16KB](FanpumpEPCsolenoid:Shortcircuit).............................................37
Failurecode[DX16KY](FanpumpEPCsolenoid:Shortcircuitwithpowersupplyline)........38
Failurecode[DXH1KA](LockupECMVsolenoid:Disconnection)..........................................40
Failurecode[DXH1KB](LockupECMVsolenoid:Shortcircuit)..............................................42
Failurecode[DXH1KY](LockupECMVsolenoid:Shortcircuitwithpowersupplyline).........44
Failurecode[DXH4KA](1stclutchECMVsolenoid:Disconnection)......................................46
Failurecode[DXH4KB](1stclutchECMVsolenoid:Shortcircuit)..........................................48
Failurecode[DXH4KY](1stclutchECMVsolenoid:Shortcircuitwithpowersupplyline)......50
Troubleshootingbyfailurecode(Displayofcode),Part10SEN01257-02
Failurecode[DXH5KA](2ndclutchECMVsolenoid:Disconnection).....................................4
Failurecode[DXH5KB](2ndclutchECMVsolenoid:Shortcircuit).........................................6
Failurecode[DXH5KY](2ndclutchECMVsolenoid:Shortcircuitwithpowersupplyline).....8
Failurecode[DXH6KA](3rdclutchECMVsolenoid:Disconnection)......................................10
Failurecode[DXH6KB](3rdclutchECMVsolenoid:Shortcircuit)..........................................12
Failurecode[DXH6KY](3rdclutchECMVsolenoid:Shortcircuitwithpowersupplyline)......14
Failurecode[DXH7KA](RclutchECMVsolenoid:Disconnection).........................................16
Failurecode[DXH7KB](RclutchECMVsolenoid:Shortcircuit)............................................18
Failurecode[DXH7KY](RclutchECMVsolenoid:Shortcircuitwithpowersupplyline)........20
Failurecode[DXH8KA](FclutchECMVsolenoid:Disconnection).........................................22
Failurecode[DXH8KB](FclutchECMVsolenoid:Shortcircuit).............................................24
Failurecode[DXH8KY](FclutchECMVsolenoid:Shortcircuitwithpowersupplyline).........26
Failurecode[DXHHKA](4thclutchECMVsolenoid:Disconnection)......................................28
Failurecode[DXHHKB](4thclutchECMVsolenoid:Shortcircuit).........................................30
Failurecode[DXHHKY](4thclutchECMVsolenoid:Shortcircuitwithpowersupplyline).....32
Failurecode[DXHLKA](JoysticksteeringrightEPCsolenoid:Disconnection)......................34
Failurecode[DXHLKB](JoysticksteeringrightEPCsolenoid:Shortcircuit)..........................36
Failurecode[DXHLKY](JoysticksteeringrightEPCsolenoid: Shortcircuitwithpowersupplyline)...................................................................38
Failurecode[DXHMKA](JoysticksteeringleftEPCsolenoid:Disconnection).......................40
Failurecode[DXHMKB](JoysticksteeringleftEPCsolenoid:Shortcircuit)...........................42
Failurecode[DXHMKY](JoysticksteeringleftEPCsolenoid: Shortcircuitwithpowersupplyline)...................................................................44
Failurecode[DY30MA]Motor-drivenemergencysteeringpumpfailure (Duringoperationofmachine)............................................................................46
Failurecode[DY30MC]Motor-drivenemergencysteeringpumpfailure (Malfunctioninmanualmode)............................................................................49
Troubleshootingofelectricalsystem(E-mode)SEN01258-03 Installingpositionsoffuses......................................................................................................3
Informationintroubleshootingtable.........................................................................................6
E-1Enginedoesnotstart........................................................................................................7
E-2Wiperdoesnotoperate.....................................................................................................14
E-3Windshieldwasherdoesnotoperate................................................................................18
E-4Headlamp,clearancelamp,taillamp,andlicenselampdonotlightuporgooff.............21
E-5Workinglampdoesnotlightuporgooff...........................................................................29
E-6Turnsignallampandhazardlampdonotlightuporgooff..............................................34
E-7Brakelampdoesnotlightoritkeepslightingup...............................................................40
E-8Backuplampdoesnotlightoritkeepslightingup............................................................42
E-9Backupbuzzerdoesnotsoundoritkeepssounding........................................................44
E-10Horndoesnotsoundoritkeepssounding......................................................................46
E-11Alarmbuzzerdoesnotsoundoritkeepssounding.........................................................48
E-12Airconditionerdoesnotoperateorstop.........................................................................50
E-13TheKOMTRAXsystemdoesnotworkproperly.............................................................53
E-14Whenkick-downswitchisturnedON,kick-downoperationdoesnotstart.....................56
E-15Whenholdswitchispressed,holdingoperationdoesnotstart......................................58
E-16Transmissioniskeptinneutral,orbrakedrags whendirectionalleverisoperatedwhileparkingbrakeisapplied.....................60
E-17Transmissioncut-offmodecannotbesetorreset..........................................................62
E-18Transmissioncut-offsetcannotbereset........................................................................64
E-19FNRswitchmodecannotbesetorreset........................................................................66
E-20Fanreversefunctioncannotbeusedorreset.................................................................68
E-21Dischargefromloaderpumpdoesnotrisefromminimumlevel.....................................70
E-22ECSSfunctioncannotbeusedorreset..........................................................................72
E-23WhenparkingbrakeisturnedON,parkingbrakeindicatorlampdoesnotlightup........74
E-24Whenemergencybrakeoperates,brakeoilpressurecautionlampdoesnotoperate...78
E-25Aircleanercloggingindicatorlampdoesnotlightup......................................................80
E-26Radiatorcoolantlevelcautionlampdoesnotlightup.....................................................82
E-27Hydraulicoiltemperaturegaugedoesnotriseand hydraulicoiltemperaturecautionlampdoesnotlightup...................................83
E-28Torqueconverteroiltemperaturegaugedoesnotriseand torqueconverteroiltemperaturecautionlampdoesnotlightup.......................84
E-29Steeringoilpressurecautionlampdoesnotlightup......................................................86
E-30Abnormalityintswitch(panelswitch1)input.................................................................88
E-31AbnormalityinUswitch(panelswitch2)input................................................................90
E-32Abnormalityin<switch(panelswitch3)input................................................................92
E-33Abnormalityin>switch(panelswitch4)input................................................................94
Troubleshootingofhydraulicandmechanicalsystem(H-mode)SEN01259-03
Methodofusingtroubleshootingchart....................................................................................3
Tableoffailuremodesandcauses..........................................................................................6
H-1Themachinedoesnotstart..............................................................................................10
H-2Torqueconverterlockupisnotswitchedoff(enginestalls) [Machinewithlockupclutch(ifequipped)]........................................................................12
H-3Torqueconverterlockupisnotswitchedon[Machinewithlockupclutch(ifequipped)]...13
H-4Thetravelspeedisslow,thethrustingforceisweak, theuphilltravelingpowerisweak,andthegearisnotshifted...........................14
H-5Shocksarelargeatthetimesofstartingandshiftinggear...............................................16
H-6Timelagislargeatthetimesofstartingandshiftinggear................................................18
H-7Thetorqueconverteroiltemperatureishigh....................................................................20
H-8Steeringdoesnotturn.......................................................................................................21
H-9Steeringdoesnotturn[Machinewithjoysticksteering(ifequipped)]...............................22
H-10Steeringresponseislow.................................................................................................23
H-11Turning,responseofsteeringispoor[machinewithjoysticksteering(ifequipped)]......24
H-12Steeringisheavy............................................................................................................25
H-13Whenmachineturns,itshakesormakeslargeshocks..................................................26
H-14Whenmachineturns,itshakesormakeslargeshocks [machinewithjoysticksteering(ifequipped)]...................................................................27
H-15Thewheelbrakedoesnotworkordoesnotworkwell...................................................28
H-16Thewheelbrakeisnotreleasedoritdrags....................................................................29
H-17Theparkingbrakedoesnotworkordoesnotworkwell.................................................30
H-18Theparkingbrakeisnotreleasedoritdrags(includingemergencyreleasesystem)....31
H-19Liftarmdoesnotrise......................................................................................................32
H-20Liftarmspeedisloworrisingforceofliftarmisinsufficient...........................................33
H-21Whenrising,theliftarmcomestomoveslowlyatspecificheight..................................34
H-22Theliftarmcylindercannotholddownthebucket(Bucketfloats)..................................34
H-23Hydraulicdriftsoftheliftarmislarge..............................................................................34
H-24Theliftarmwobblesduringoperation.............................................................................34
H-25Bucketdoesnottiltback.................................................................................................35
H-26Bucketspeedislowortiltingbackforceisinsufficient...................................................36
H-27Thebucketcomestooperateslowlyinthemidstoftilting-back.....................................37
H-28Thebucketcylindercannotholddownthebucket..........................................................37
H-29Hydraulicdriftsofthebucketislarge..............................................................................37
H-30Thebucketwobblesduringtravelwithcargo (Theworkequipmentvalveissetto"HOLD")..................................................................37
H-31Liftarmandbucketcontrolleversdonotmovesmoothlyandareheavy.......................38
H-32Duringoperationofthemachine,enginespeedlowersremarkablyorenginestalls......39
H-33Largeshockismadewhenworkequipmentstartsandstops........................................39
H-34Whenworkequipmentcircuitisrelievedsingly,otherworkequipmentmoves..............39
H-35ECSSdoesnotoperate,andpitching,bouncingoccur..................................................40
Troubleshootingofengine(S-mode)SEN01260-02
Methodofusingtroubleshootingcharts...................................................................................3
S-1Enginedoesnotstarteasily..............................................................................................6
S-2Enginedoesnotstart........................................................................................................7
S-3Enginedoesnotpickupsmoothly....................................................................................10