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KOMATSU LW250-5 SHOP MANUAL SEBM008905 – PDF DOWNLOAD
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Description
KOMATSU LW250-5 SHOP MANUAL SEBM008905 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU LW250-5 SHOP MANUAL SEBM008905 – PDF DOWNLOAD
Language : English
Pages : 1910
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU LW250-5 SHOP MANUAL SEBM008905 – PDF DOWNLOAD
COVER................................................................................................................................................................................... 1 CONTENTS................................................................................................................................................................................ 2 01 GENERAL.............................................................................................................................................................................. 28 SPECIFICATION DRAWING............................................................................................................................................................... 29 SPECIFICATIONS...................................................................................................................................................................... 33 WORKING RADIUS-LIFTING HEIGHT CHART................................................................................................................................................. 39 RATED OVERALL LOAD TABLE............................................................................................................................................................ 41 MINIMUM INTERSECTING AISLE WIDTH.................................................................................................................................................... 56 WEIGHT TABLE........................................................................................................................................................................ 58 LIST OF LUBRICANTS AND WATER........................................................................................................................................................ 60 10 STRUCTURE AND FUNCTION............................................................................................................................................................... 61 POWER TRAIN......................................................................................................................................................................... 63 ENGINE SPEED SET CYLINDER........................................................................................................................................................... 65 DAMPER.............................................................................................................................................................................. 68 TRANSMISSION HYDRAULIC PIPING DIAGRAM............................................................................................................................................... 69 TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM............................................................................................................................. 70 TORQUE CONVERTER,TRANSMISSION HYDRAULIC SYSTEM SCHEMATICS........................................................................................................................... 72 TORQUE CONVERTER.................................................................................................................................................................... 74 PTO CLUTCH.......................................................................................................................................................................... 78 TRANSMISSION........................................................................................................................................................................ 79 TRANSMISSION CONTROL VALVE.......................................................................................................................................................... 86 PROPORTIONAL SOLENOID VALVE......................................................................................................................................................... 88 AXLE................................................................................................................................................................................ 92 BRAKE............................................................................................................................................................................... 96 PARKING BRAKE....................................................................................................................................................................... 97 TIRES............................................................................................................................................................................... 99 SWING CIRCLE........................................................................................................................................................................ 100 STEERING WHEEL...................................................................................................................................................................... 101 REAR STEERING LOCK SYSTEM........................................................................................................................................................... 102 SUSPENSION SYSTEM................................................................................................................................................................... 104 AIR CIRCUIT DIAGRAM................................................................................................................................................................. 105 AIR EQUIPMENT PIPING DRAWING........................................................................................................................................................ 107 AIR GOVERNOR........................................................................................................................................................................ 109 ACCELERATOR CONTROL VALVE........................................................................................................................................................... 111 ACCELERATOR CONTROL CYLINDER........................................................................................................................................................ 114 EXHAUST BRAKE SELECTOR VALVE........................................................................................................................................................ 115 EXHAUST BRAKE BUTTERFLY VALVE....................................................................................................................................................... 116 BRAKE AIR SYSTEM.................................................................................................................................................................... 118 BRAKE CONTROL VALVE................................................................................................................................................................. 120 BRAKE BOOSTER....................................................................................................................................................................... 124 BRAKE SHUTTLE VALVE................................................................................................................................................................. 131 AUXILIARY BRAKE VALVE............................................................................................................................................................... 132 PARKING BRAKE VALVE................................................................................................................................................................. 134 PARKING BRAKE CHAMBER............................................................................................................................................................... 136 REAR STEERING LOCK AIR SYSTEM....................................................................................................................................................... 138 REAR STEERING LOCK VALVE............................................................................................................................................................ 139 REAR STEERING LOCK CYLINDER......................................................................................................................................................... 143 CENTRALIZED GREASING PUMP........................................................................................................................................................... 144 HYDRAULIC,HOT WATER,AIR CENTER SWIVEL JOINT......................................................................................................................................... 150 HYDRAULIC CIRCUIT DIAGRAM........................................................................................................................................................... 152 WORK EQUIPMENT,STEERING HYDRAULIC EQUIPMENT DRAWING................................................................................................................................. 156 MAIN CONTROL VALVE.................................................................................................................................................................. 159 SWING HYDRAULIC SYSTEM.............................................................................................................................................................. 162 SWING VALVE......................................................................................................................................................................... 164 SWING MOTOR,MACHINERY............................................................................................................................................................... 165 SWING HOLDING BRAKE AND BRAKE SOLENOID VALVE........................................................................................................................................ 166 SWING BRAKE VALVE................................................................................................................................................................... 168 SWING FREE/LOCK SELECTOR VALVE...................................................................................................................................................... 169 STEERING HYDRAULIC SYSTEM........................................................................................................................................................... 170 STEERING UNIT....................................................................................................................................................................... 172 PRIORITY VALVE...................................................................................................................................................................... 180 STEERING MODE SELECTOR VALVE........................................................................................................................................................ 183 REAR WHEEL STEERING SELECTOR VALVE.................................................................................................................................................. 189 REVERSE STEERING COMPENSATION VALVE................................................................................................................................................. 191 SUSPENSION HYDRAULIC SYSTEM......................................................................................................................................................... 194 SUSPENSION SELECTOR VALVE........................................................................................................................................................... 196 SUSPENSION LOCK VALVE............................................................................................................................................................... 198 SUSPENSION PILOT CHECK VALVE........................................................................................................................................................ 200 OUTRIGGER HYDRAULIC SYSTEM.......................................................................................................................................................... 205 OUTRIGGER SELECTOR VALVE............................................................................................................................................................ 207 COLLECTION CHECK VALVE.............................................................................................................................................................. 216 OUTRIGGER INDIVIDUAL VALVE.......................................................................................................................................................... 218 OUTRIGGER MERGE SELECTOR VALVE...................................................................................................................................................... 220 OUTRIGGER JACK PILOT CHECK VALVE.................................................................................................................................................... 222 PEDAL PPC VALVE..................................................................................................................................................................... 224 LEVER PPC VALVE..................................................................................................................................................................... 227 RELIEF VALVE........................................................................................................................................................................ 232 BOOM HYDRAULIC SYSTEM............................................................................................................................................................... 233 UNLOAD PILOT VALVE.................................................................................................................................................................. 235 BOOM TELESCOPE SELECTOR VALVE....................................................................................................................................................... 237 BOOM CYLINDER....................................................................................................................................................................... 246 WINCH HYDRAULIC SYSTEM.............................................................................................................................................................. 252 WINCH MOTOR......................................................................................................................................................................... 254 WINCH CLUTCH VALVE.................................................................................................................................................................. 258 WINCH BRAKE MASTER CYLINDER......................................................................................................................................................... 263 OVERRUN PREVENTION VALVE............................................................................................................................................................ 267 FLOW PRIORITY VALVE................................................................................................................................................................. 270 CHARGE VALVE........................................................................................................................................................................ 271 AIR CONDITIONER..................................................................................................................................................................... 275 BOOM................................................................................................................................................................................ 276 JIB................................................................................................................................................................................. 281 MAIN HOOK........................................................................................................................................................................... 285 AUXILIARY HOOK...................................................................................................................................................................... 286 WINCH............................................................................................................................................................................... 287 WINCH DRUM.......................................................................................................................................................................... 288 WINCH CLUTCH........................................................................................................................................................................ 289 WINCH BRAKE......................................................................................................................................................................... 290 CHASSIS,X-SHAPED OUTRIGGER.......................................................................................................................................................... 291 REVOLVING FRAME,GUIDE SHEAVE........................................................................................................................................................ 293 ELECTRIC CIRCUIT DIAGRAM............................................................................................................................................................ 295 ELECTRICAL COMPONENT DIAGRAM........................................................................................................................................................ 296 OVERWIND PREVENTION SYSTEM DRAWING.................................................................................................................................................. 299 OVERLOAD SAFETY SYSTEM DRAWING...................................................................................................................................................... 300 ELECTRIC SWIVEL JOINT(SLIP RING).................................................................................................................................................... 301 MULTIPLE DATA TRANSFER (MDT) SYSTEM................................................................................................................................................. 303 AUTOMATIC GEAR SHIFT SYSTEM(AESC)................................................................................................................................................... 308 GEAR SHIFT LEVER(TRIM SWITCH)....................................................................................................................................................... 310 MOMENT LIMITER(OVERLOAD PREVENTION SYSTEM).......................................................................................................................................... 312 OUTLINE,OPERATION OF ELECTRIC CIRCUITS.............................................................................................................................................. 356 20 TESTING AND ADJUSTING................................................................................................................................................................ 444 STANDARD VALUE TABLE FOR ENGINE..................................................................................................................................................... 445 STANDARD VALUE TABLE FOR CHASSIS.................................................................................................................................................... 446 STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS................................................................................................................................... 451 TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING FOR ENGINE.......................................................................................................................... 496 ADJUSTING VALVE CLEARANCE........................................................................................................................................................... 497 MEASURING COMPRESSION PRESSURE...................................................................................................................................................... 498 TESTING AND ADJUSTING FUEL INJECTION TIMING......................................................................................................................................... 499 MEASURING ENGINE OIL PRESSURE....................................................................................................................................................... 501 TESTING AND ADJUSTING FAN BELT TENSION.............................................................................................................................................. 502 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION....................................................................................................................... 502 MEASURING ENGINE SPEED.............................................................................................................................................................. 503 MEASURING BLOW-BY PRESSURE.......................................................................................................................................................... 504 MEASURING EXHAUST TEMPERATURE....................................................................................................................................................... 505 MEASURING EXHAUST COLOR............................................................................................................................................................. 506 MEASURING OIL PRESSURE.............................................................................................................................................................. 507 MEASURING LEAKAGE OF OIL............................................................................................................................................................ 521 PROCEDURE FOR FLUSHING HYDRAULIC OIL................................................................................................................................................ 524 MEASURING AND ADJUSTING AIR PRESSURE................................................................................................................................................ 526 BLEEDING AIR........................................................................................................................................................................ 528 MEASURING STEERING WHEEL PLAY....................................................................................................................................................... 534 ADJUSTING MINIMUM TURNING RADIUS OF STEERING........................................................................................................................................ 535 TESTING AND ADJUSTING TOE-IN........................................................................................................................................................ 536 TESTING AND ADJUSTING PARKING BRAKE EFFECT.......................................................................................................................................... 537 ADJUSTING ENGINE CONTROL ........................................................................................................................................................... 538 METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE........................................................................................................................................ 540 ADJUSTING BRAKE PEDAL............................................................................................................................................................... 542 ADJUSTING WINCH BRAKE............................................................................................................................................................... 543 ADJUSTING WINCH DRUM LOCK........................................................................................................................................................... 546 ADJUSTING MAIN,AUXILIARY WINCH CLUTCH............................................................................................................................................... 547 ADJUSTING TELESCOPE/AUXILIARY WINCH PEDAL........................................................................................................................................... 550 ADJUSTING LEVER STAND,LOCK LEVER.................................................................................................................................................... 551 ADJUSTING TELESCOPE WIRE ROPE....................................................................................................................................................... 552 ADJUSTING LIMIT SWITCH.............................................................................................................................................................. 554 TESTING AND ADJUSTING PROXIMITY SWITCH.............................................................................................................................................. 557 CHECKS BEFORE STARTING FOR OVERLOAD PREVENTION SYSTEM............................................................................................................................... 559 SETTING MODEL SELECTOR SWITCH FOR OVERLOAD SAFETY SYSTEM............................................................................................................................ 561 METHOD OF DISPLAYING SERVICE MODE FOR OVERLOAD PREVENTION SYSTEM.................................................................................................................... 562 TROUBLESHOOTING..................................................................................................................................................................... 575 POINTS TO REMEMBER WHEN TROUBLESHOOTING......................................................................................................................................... 576 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................................................................... 577 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE................................................................................................................................ 578 CHECKS BEFORE TROUBLESHOOTING................................................................................................................................................... 586 CONNECTOR TYPES AND MOUNTING LOCATIONS.......................................................................................................................................... 587 CONNECTOR ARRANGEMENT DIAGRAM................................................................................................................................................... 595 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...................................................................................................................................... 598 EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM.............................................................................................................. 608 DISPLAY METHOD FOR SELF-DIAGNOSIS(ERROR CODES) AND SAVING TO MEMORY............................................................................................................. 616 TABLE OF ERROR CODES,RE-ENACTION................................................................................................................................................ 619 METHOD OF USING JUDGEMENT TABLE................................................................................................................................................. 628 METHOD OF USING TROUBLESHOOTING CHARTS.......................................................................................................................................... 629 TROUBLESHOOTING OF ENGINE SYSTEM(S MODE)........................................................................................................................................ 631 METHOD OF USING TROUBLESHOOTING CHART....................................................................................................................................... 632 S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)................................................................................................................ 636 S-2 ENGINE DOES NOT START................................................................................................................................................... 638 (1)ENGINE DOES NOT TURN................................................................................................................................................. 638 (2)ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED).............................................................................................. 639 (3)EXHAUST SMOKE COMES OUT,BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED)............................................................................................ 640 S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)..................................................................................................................... 641 S-4 ENGINE STOPS DURING OPERATIONS.......................................................................................................................................... 642 S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)................................................................................................................................ 643 S-6 ENGINE LACKS OUTPUT(NO POWER)........................................................................................................................................... 644 S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)........................................................................................................................... 645 S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE).................................................................................................................. 646 S-9 OIL BECOMES CONTAMINATED QUICKLY........................................................................................................................................ 647 S-10 FUEL CONSUMPTION IS EXCESSIVE.......................................................................................................................................... 648 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN.................................................................................................. 649 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE).............................................................................................................. 650 S-13 OIL LEVEL RISES(WATER,FUEL IN OIL)..................................................................................................................................... 651 S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)........................................................................................................................ 652 S-15 ABNORMAL NOISE IS MADE................................................................................................................................................. 653 S-16 VIBRATION IS EXCESSIVE................................................................................................................................................. 654 TROUBLESHOOTING OF UPPER MDT CONTROLLER SYSTEM(EU MODE)......................................................................................................................... 655 TABLE OF ERROR CODES AND TROUBLESHOOTING CODES.............................................................................................................................. 657 ACTION OF CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS....................................................................................................... 666 JUDGEMENT TABLE FOR UPPER MDT,AND HYDRAULIC AND MECHANICAL SYSTEMS.......................................................................................................... 684 ELECTRICAL CIRCUIT DIAGRAM OF POWER SOURCE,STARTING,CHARGING,AND PREHEATING SYSTEMS......................................................................................... 688 ELECTRICAL CIRCUIT DIAGRAM OF NETWORK SYSTEM................................................................................................................................ 690 ELECTRICAL CIRCUIT DIAGRAM OF BRAKE SYSTEM.................................................................................................................................. 691 ELECTRICAL CIRCUIT DIAGRAM OF STEERING SYSTEM............................................................................................................................... 692 ELECTRICAL CIRCUIT DIAGRAM OF SUSPENSION SYSTEM............................................................................................................................. 694 ELECTRICAL CIRCUIT DIAGRAM OF OUTRIGGER SYSTEM.............................................................................................................................. 695 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE MONITOR SYSTEM........................................................................................................................ 697 ELECTRICAL CIRCUIT DIAGRAM OF TURN SIGNAL AND SWING FLASHER SYSTEMS......................................................................................................... 699 ELECTRICAL CIRCUIT DIAGRAM OF LAMP,HORN,AND GREASE SYSTEMS.................................................................................................................. 701 EU- 1 MDTU ERROR E00 (MDT SYSTEM ERROR)IS DISPLAYED......................................................................................................................... 703 EU- 2 MDTU ERROR E10 (SHUT OFF WHEN LOW VOLTAGE)IS DISPLAYED................................................................................................................ 703 EU- 3 MDTU ERROR E11 (SHUT OFF WHEN HIGH TEMPERATURE)IS DISPLAYED........................................................................................................... 704 EU- 4 MDTU ERROR E20 (TOP,BOTTOM DON'T MATCH(APPLICATION STOPPED))IS DISPLAYED.............................................................................................. 705 EU- 5 MDTU ERROR E21 (TOP,BOTTOM SELECTION WARNING)IS DISPLAYED............................................................................................................. 706 EU- 6 MDTU ERROR E24 (MODEL DOESN'T MATCH(APPLICATION STOPPED))IS DISPLAYED................................................................................................. 707 EU- 7 MDTU ERROR E25 (MODEL SELECTION WARNING)IS DISPLAYED.................................................................................................................. 708 EU- 8 MDTU ERROR E28 (ABNORMALITY IN C-NET COMMUNICATION BETWEEN MDTS(OUTPUT STOPPED))IS DISPLAYED.......................................................................... 709 EU- 9 MDTU ERROR E29 (ABNORMALITY IN S-NET COMMUNICATION BETWEEN MDT AND MOMENT LIMITER)IS DISPLAYED........................................................................ 710 EU-10 MDTU ERROR E40 (SWING FLASHER OUTPUT SHORT CIRCUITED WITH GROUND)IS DISPLAYED......................................................................................... 711 EU-11 MDTU ERROR E41 (POWER SOURCE FOR OUTRIGGER PANEL SHORT CIRCUITED WITH GROUND)IS DISPLAYED............................................................................. 712 EU-13 MDTU ERROR E43 (OUTRIGGER MODE POWER SOURCE SHORT CIRCUITED WITH GROUND)IS DISPLAYED.................................................................................. 713 EU-14 MDTU ERROR E44 (CRAB MODE DISPLAY LED SHORT CIRCUITED WITH GROUND)IS DISPLAYED........................................................................................ 714 EU-15 MDTU ERROR E45 (FRONT WHEEL MODE DISPLAY LED SHORT CIRCUITED WITH GROUND)IS DISPLAYED................................................................................. 714 EU-16 MDTU ERROR E46 (REAR WHEEL MODE DISPLAY LED SHORT CIRCUITED WITH GROUND)IS DISPLAYED.................................................................................. 715 EU-17 MDTU ERROR E47 (4-WHEEL MODE DISPLAY LED SHORT CIRCUITED WITH GROUND)IS DISPLAYED..................................................................................... 715 EU-18 MDTU ERROR E48 (REAR STEERING [WHEEL] LOCK LED SHORT CIRCUITED WITH GROUND)IS DISPLAYED............................................................................... 716 EU-19 MDTU ERROR E49 (REAR STEERING [WHEEL] FREE LED SHORT CIRCUITED WITH GROUND)IS DISPLAYED............................................................................... 716 EU-20 MDTU ERROR E4A (REAR STEERING [WHEEL] CENTER LED SHORT CIRCUITED WITH GROUND)IS DISPLAYED............................................................................. 717 EU-21 MDTU ERROR E4B (REVERSE STEERING DISPLAY LED SHORT CIRCUITED WITH GROUND)IS DISPLAYED................................................................................. 718 EU-22 MDTU ERROR E4C (WINCH ROTATION BUZZER(MAIN WINCH)SHORT CIRCUITED WITH GROUND) IS DISPLAYED............................................................................ 718 EU-23 MDTU ERROR E4D (EMERGENCY ALARM BUZZER SHORT CIRCUITED WITH GROUND)IS DISPLAYED....................................................................................... 719 EU-24 MDTU ERROR E4E (WINCH ROTATION BUZZER(AUXILIARY WINCH) SHORT CIRCUITED WITH GROUND)IS DISPLAYED....................................................................... 720 EU-25 MDTU ERROR E4F (MONITOR CENTRAL BUZZER SHORT CIRCUITED WITH GROUND)IS DISPLAYED....................................................................................... 721 EU-26 MDTU ERROR E50 (TACHOMETER SIGNAL OUTPUT SYSTEM SHORT CIRCUITED)IS DISPLAYED.......................................................................................... 722 EU-27 MDTU ERROR E51 (SPEEDOMETER SIGNAL OUTPUT SYSTEM SHORT CIRCUITED)IS DISPLAYED......................................................................................... 723 EU-28 MDTU ERROR E52 (FUEL LEVEL SIGNAL OUTPUT SYSTEM SHORT CIRCUITED)IS DISPLAYED.......................................................................................... 724 EU-29 MDTU ERROR E53 (ENGINE WATER TEMPERATURE SIGNAL OUTPUT SYSTEM SHORT CIRCUITED)IS DISPLAYED............................................................................ 725 EU-30 MDTU ERROR E55 (TORQUE CONVERTER OIL TEMPERATURE OUTPUT SYSTEM SHORT CIRCUITED)IS DISPLAYED........................................................................... 726 EU-31 MDTU ERROR E56 (ENGINE OIL PRESSURE OUTPUT SYSTEM SHORT CIRCUITED)IS DISPLAYED........................................................................................ 727 EU-32 MDTU ERROR E57 (PREHEATING PILOT SIGNAL OUTPUT SYSTEM SHORT CIRCUITED)IS DISPLAYED.................................................................................... 728 EU-33 MDTU ERROR E58 (PARKING BRAKE ACTUATION LAMP OUTPUT SYSTEM SHORT CIRCUITED)IS DISPLAYED............................................................................... 729 EU-35 MDTU ERROR E5A (HI BEAM PILOT OUTPUT SYSTEM SHORT CIRCUITED WITH GROUND)IS DISPLAYED.................................................................................. 730 EU-36 MDTU ERROR E5B (HOURMETER OUTPUT SYSTEM SHORT CIRCUITED WITH GROUND)IS DISPLAYED...................................................................................... 731 EU-37 MDTU ERROR E5C (CHARGE LAMP OUTPUT SYSTEM SHORT CIRCUITED WITH GROUND)IS DISPLAYED.................................................................................... 732 EU-38 MDTU ERROR E5D (BRAKE FLUID (OIL) LEVEL OUTPUT LAMP SHORT CIRCUITED WITH GROUND)IS DISPLAYED.......................................................................... 733 EU-39 MDTU ERROR E5E (RIGHT TURN PILOT SHORT CIRCUITED WITH GROUND)IS DISPLAYED............................................................................................. 734 EU-40 MDTU ERROR E5F (LEFT TURN PILOT SHORT CIRCUITED WITH GROUND)IS DISPLAYED.............................................................................................. 735 EU-41 MDTU ERROR E72/E1E (LED DIMMER 1 [SHIFT POSITION DISPLAY LED SYSTEM] SHORT CIRCUITED WITH GROUND)IS DISPLAYED......................................................... 736 EU-42 MDTU ERROR E73/E1E (LED DIMMER 2 [SHIFT POSITION DISPLAY LED SYSTEM] SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED................................................... 736 EU-43 MDTU ERROR E74/E1F (LED DIMMER 2 [REAR WHEEL LOCK LED SYSTEM SHORT CIRCUITED WITH GROUND)IS DISPLAYED................................................................. 737 EU-44 MDTU ERROR E75/E1F (LED DIMMER 2 [REAR WHEEL LOCK LED SYSTEM SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED........................................................... 737 EU-46 MDTU ERROR E80 (SWING FLASHER OUTPUT SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED................................................................................... 738 EU-47 MDTU ERROR E83 (OUTRIGGER MODE POWER SOURCE SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED............................................................................ 739 EU-48 MDTU ERROR EB3 (DISCONNECTION IN OUTRIGGER MODE POWER SOURCE)IS DISPLAYED............................................................................................. 740 EU-49 MDTU ERROR EE0 (PTO MODE DOESN'T MATCH)IS DISPLAYED................................................................................................................... 741 EU-50 MDTU ERROR EE1 (ABNORMALITY IN 2WD HI/4WD HI/4WD LO SIGNAL)IS DISPLAYED............................................................................................... 743 EU-51 MDTU ERROR EE3 (ABNORMALITY IN SERVICE BRAKE INPUT)IS DISPLAYED....................................................................................................... 744 EU-52 MDTU ERROR EE4 (ABNORMALITY IN SUSPENSION LIFT SWITCH)IS DISPLAYED.................................................................................................... 745 EU-53 MDTU ERROR EE5 (ABNORMALITY IN OUTRIGGER CONTROL SWITCH)IS DISPLAYED.................................................................................................. 746 EU-54 MDTU ERROR EE6 (TOP OUTRIGGER EXTEND+RETRACT SWITCHES INPUT SIMULTANEOUSLY)IS DISPLAYED,MDTU ERROR EE6 (TOP OUTRIGGER JACK+SLIDE INPUT SIMULTANEOUSLY)IS DISPLAYED.... 749 EU-55 MDTU ERROR EEA (ABNORMALITY IN STEERING MODE SWITCH INPUT)IS DISPLAYED................................................................................................ 752 EU-56 MDTU ERROR EEC (REAR STEERING LOCK+FREE COMMANDS INPUT SIMULTANEOUSLY)IS DISPLAYED.................................................................................... 754 TROUBLESHOOTING OF LOWER MDT CONTROLLER SYSTEM(EL MODE)......................................................................................................................... 755 TABLE OF ERROR CODES AND TROUBLESHOOTING CODES.............................................................................................................................. 757 ACTION OF CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS....................................................................................................... 766 JUDGEMENT TABLE FOR LOWER MDT,AND HYDRAULIC AND MECHANICAL SYSTEMS(1/2)..................................................................................................... 802 JUDGEMENT TABLE FOR LOWER MDT,AND HYDRAULIC AND MECHANICAL SYSTEMS(2/2)..................................................................................................... 804 ELECTRICAL CIRCUIT DIAGRAM OF POWER SOURCE,STARTING,CHARGING,AND PREHEATING SYSTEMS......................................................................................... 808 ELECTRICAL CIRCUIT DIAGRAM OF NETWORK SYSTEM................................................................................................................................ 810 ELECTRICAL CIRCUIT DIAGRAM OF BRAKE SYSTEM.................................................................................................................................. 811 ELECTRICAL CIRCUIT DIAGRAM OF STEERING SYSTEM............................................................................................................................... 812 ELECTRICAL CIRCUIT DIAGRAM OF SUSPENSION SYSTEM............................................................................................................................. 814 ELECTRICAL CIRCUIT DIAGRAM OF OUTRIGGER SYSTEM.............................................................................................................................. 815 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE MONITOR SYSTEM........................................................................................................................ 817 ELECTRICAL CIRCUIT DIAGRAM OF TURN SIGNAL AND SWING FLASHER SYSTEMS......................................................................................................... 819 ELECTRICAL CIRCUIT DIAGRAM OF LIGHTING AND HORN SYSTEMS..................................................................................................................... 821 EL- 1 MDTL ERROR E00 (MDT SYSTEM ERROR)IS DISPLAYED......................................................................................................................... 823 EL- 2 MDTL ERROR E10 (SHUT OFF WHEN LOW VOLTAGE)IS DISPLAYED................................................................................................................ 823 EL- 3 MDTL ERROR E11 (SHUT OFF WHEN HIGH TEMPERATURE)IS DISPLAYED........................................................................................................... 824 EL- 4 MDTL ERROR E18 (DISCONNECTION IN TACHOMETER SENSOR)IS DISPLAYED....................................................................................................... 825 EL- 5 MDTL ERROR E19 (DISCONNECTION IN SPEEDOMETER SENSOR 2)IS DISPLAYED.................................................................................................... 826 EL- 6 MDTL ERROR E20 (TOP,BOTTOM DONT'T MATCH (APPLICATION STOPPED))IS DISPLAYED............................................................................................ 827 EL- 7 MDTL ERROR E21 (TOP,BOTTOM SELECTION WARNING)IS DISPLAYED............................................................................................................. 827 EL- 8 MDTL ERROR E24 (MODEL DOESN'T MATCH (APPLICATION STOPPED))IS DISPLAYED................................................................................................ 828 EL- 9 MDTL ERROR E25 (MODEL SELECTION WARNING)IS DISPLAYED.................................................................................................................. 828 EL-10 MDTL ERROR E28 (ABNORMALITY IN C-NET COMMUNICATION BETWEEN MDTS)IS DISPLAYED.......................................................................................... 829 EL-11 MDTL ERROR E29 (ABNORMALITY IN S-NET COMMUNICATION BETWEEN MDT AND TRANSMISSION CONTROLLER)IS DISPLAYED............................................................... 830 EL-22 MDTL ERROR E40 (OUTRIGGER JACK RL SHORT CIRCUITED WITH GROUND)IS DISPLAYED............................................................................................ 831 EL-23 MDTL ERROR E41 (OUTRIGGER JACK FL SHORT CIRCUITED WITH GROUND)IS DISPLAYED............................................................................................ 833 EL-24 MDTL ERROR E42 (OUTRIGGER JACK RR SHORT CIRCUITED WITH GROUND)IS DISPLAYED............................................................................................ 835 EL-25 MDTL ERROR E43 (OUTRIGGER JACK FR SHORT CIRCUITED WITH GROUND)IS DISPLAYED............................................................................................ 837 EL-26 MDTL ERROR E44 (OUTRIGGER SLIDE RL SHORT CIRCUITED WITH GROUND)IS DISPLAYED........................................................................................... 839 EL-27 MDTL ERROR E45 (OUTRIGGER SLIDE FL SHORT CIRCUITED WITH GROUND)IS DISPLAYED........................................................................................... 840 EL-28 MDTL ERROR E46 (OUTRIGGER SLIDE RR SHORT CIRCUITED WITH GROUND)IS DISPLAYED........................................................................................... 841 EL-29 MDTL ERROR E47 (OUTRIGGER SLIDE FR SHORT CIRCUITED WITH GROUND)IS DISPLAYED........................................................................................... 842 EL-30 MDTL ERROR E48 (OUTRIGGER SELECTOR EXTEND SHORT CIRCUITED WITH GROUND)IS DISPLAYED.................................................................................... 843 EL-31 MDTL ERROR E49 (OUTRIGGER SELECTOR STOW SHORT CIRCUITED WITH GROUND)IS DISPLAYED...................................................................................... 844 EL-32 MDTL ERROR E4A (REAR STEERING LOCK SOLENOID SHORT CIRCUITED WITH GROUND)IS DISPLAYED.................................................................................. 845 EL-33 MDTL ERROR E4B (REAR STEERING FREE SOLENOID SHORT CIRCUITED WITH GROUND)IS DISPLAYED.................................................................................. 846 EL-34 MDTL ERROR E4C (SERVICE BRAKE SOLENOID SHORT CIRCUITED WITH GROUND)IS DISPLAYED....................................................................................... 847 EL-35 MDTL ERROR E4D (EXHAUST BRAKE SOLENOID SHORT CIRCUITED WITH GROUND)IS DISPLAYED....................................................................................... 848 EL-37 MDTL ERROR E4F (PREHEATING [HEATER RELAY CIRCUIT] SHORT CIRCUITED WITH GROUND)IS DISPLAYED............................................................................ 849 EL-38 MDTL ERROR E50 (ELECTRIC STOWING MIRROR SET RELAY SHORT CIRCUITED WITH GROUND)IS DISPLAYED............................................................................ 850 EL-40 MDTL ERROR E52 (ELECTRIC STOWING MIRROR STOWING RELAY SHORT CIRCUITED WITH GROUND)IS DISPLAYED........................................................................ 851 EL-43 MDTL ERROR E5A (HEAD LAMP HI RELAY SHORT CIRCUITED WITH GROUND)IS DISPLAYED........................................................................................... 852 EL-44 MDTL ERROR E5B (HEAD LAMP LO RELAY SHORT CIRCUITED WITH GROUND)IS DISPLAYED........................................................................................... 853 EL-45 MDTL ERROR E5C (SIDE LAMP RELAY SHORT CIRCUITED WITH GROUND)IS DISPLAYED.............................................................................................. 854 EL-47 MDTL ERROR E5E (RIGHT TURN RELAY SHORT CIRCUITED WITH GROUND)IS DISPLAYED............................................................................................. 855 EL-48 MDTL ERROR E5F (LEFT TURN RELAY SHORT CIRCUITED WITH GROUND)IS DISPLAYED.............................................................................................. 856 EL-49 MDTL ERROR E60 (STEERING MODE SOLENOID A SHORT CIRCUITED WITH GROUND)IS DISPLAYED..................................................................................... 857 EL-50 MDTL ERROR E61 (STEERING MODE SOLENOID C SHORT CIRCUITED WITH GROUND)IS DISPLAYED..................................................................................... 858 EL-51 MDTL ERROR E62 (STEERING MODE SOLENOID B SHORT CIRCUITED WITH GROUND)IS DISPLAYED..................................................................................... 859 EL-52 MDTL ERROR E63 (STEERING MODE SOLENOID D SHORT CIRCUITED WITH GROUND)IS DISPLAYED..................................................................................... 860 EL-53 MDTL ERROR E64 (SWING PUMP MERGE SOLENOID SHORT CIRCUITED WITH GROUND)IS DISPLAYED.................................................................................... 861 EL-55 MDTL ERROR E67 (SUSPENSION LIFT SOLENOID SHORT CIRCUITED WITH GROUND)IS DISPLAYED..................................................................................... 862 EL-56 MDTL ERROR E76 (OUTRIGGER LENGTH SENSOR POWER SOURCE [5V] OUTPUT SHORT CIRCUITED WITH GROUND)IS DISPLAYED............................................................. 863 EL-57 MDTL ERROR E80 (OUTRIGGER JACK RL SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED...................................................................................... 864 EL-58 MDTL ERROR E81 (OUTRIGGER JACK FL SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED...................................................................................... 866 EL-59 MDTL ERROR E82 (OUTRIGGER JACK RR SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED...................................................................................... 868 EL-60 MDTL ERROR E83 (OUTRIGGER JACK FR SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED...................................................................................... 870 EL-61 MDTL ERROR E84 (OUTRIGGER SLIDE RL SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED..................................................................................... 872 EL-62 MDTL ERROR E85 (OUTRIGGER SLIDE FL SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED..................................................................................... 873 EL-63 MDTL ERROR E86 (OUTRIGGER SLIDE RR SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED..................................................................................... 874 EL-64 MDTL ERROR E87 (OUTRIGGER SLIDE FR SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED..................................................................................... 875 EL-65 MDTL ERROR E88 (OUTRIGGER SELECTOR EXTEND SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED.............................................................................. 876 EL-66 MDTL ERROR E89 (OUTRIGGER SELECTOR STOW SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED................................................................................ 877 EL-67 MDTL ERROR E8A (REAR STEERING LOCK SOLENOID SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED............................................................................ 878 EL-68 MDTL ERROR E8B (REAR STEERING FREE SOLENOID SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED............................................................................ 878 EL-69 MDTL ERROR E8C (SERVICE BRAKE SOLENOID SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED................................................................................. 879 EL-70 MDTL ERROR E8D (EXHAUST BRAKE SOLENOID SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED................................................................................. 879 EL-72 MDTL ERROR E8F (PREHEATING [HEATER RELAY CIRCUIT] SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED...................................................................... 880 EL-73 MDTL ERROR E9A (HEAD LAMP HI RELAY SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED..................................................................................... 881 EL-74 MDTL ERROR E9B (HEAD LAMP LO RELAY SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED..................................................................................... 882 EL-75 MDTL ERROR E9C (SIDE LAMP RELAY SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED........................................................................................ 883 EL-76 MDTL ERROR E9E (RIGHT TURN RELAY SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED....................................................................................... 884 EL-77 MDTL ERROR E9F (LEFT TURN RELAY SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED........................................................................................ 884 EL-78 MDTL ERROR EA0 (STEERING MODE SOLENOID A SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED............................................................................... 885 EL-79 MDTL ERROR EA1 (STEERING MODE SOLENOID C SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED............................................................................... 886 EL-80 MDTL ERROR EA2 (STEERING MODE SOLENOID B SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED............................................................................... 887 EL-81 MDTL ERROR EA3 (STEERING MODE SOLENOID D SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED............................................................................... 888 EL-82 MDTL ERROR EA4 (SWING PUMP MERGE SOLENOID SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED.............................................................................. 889 EL-83 MDTL ERROR EA7 (SUSPENSION LIFT SOLENOID SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED............................................................................... 890 EL-84 MDTL ERROR EB0 (DISCONNECTION IN OUTRIGGER JACK RL)IS DISPLAYED....................................................................................................... 891 EL-85 MDTL ERROR EB1 (DISCONNECTION IN OUTRIGGER JACK FL)IS DISPLAYED....................................................................................................... 893 EL-86 MDTL ERROR EB2 (DISCONNECTION IN OUTRIGGER JACK RR)IS DISPLAYED....................................................................................................... 895 EL-87 MDTL ERROR EB3 (DISCONNECTION IN OUTRIGGER JACK FR)IS DISPLAYED....................................................................................................... 897 EL-88 MDTL ERROR EB4 (DISCONNECTION IN OUTRIGGER SLIDE RL)IS DISPLAYED...................................................................................................... 899 EL-89 MDTL ERROR EB5 (DISCONNECTION IN OUTRIGGER SLIDE FL)IS DISPLAYED...................................................................................................... 900 EL-90 MDTL ERROR EB6 (DISCONNECTION IN OUTRIGGER SLIDE RR)IS DISPLAYED...................................................................................................... 901 EL-91 MDTL ERROR EB7 (DISCONNECTION IN OUTRIGGER SLIDE FR)IS DISPLAYED...................................................................................................... 902 EL-92 MDTL ERROR EB8 (DISCONNECTION IN OUTRIGGER SELECTOR EXTEND)IS DISPLAYED............................................................................................... 903 EL-93 MDTL ERROR EB9 (DISCONNECTION IN OUTRIGGER SELECTOR STOW)IS DISPLAYED................................................................................................. 904 EL-94 MDTL ERROR EBA (DISCONNECTION IN REAR STEERING LOCK SOLENOID)IS DISPLAYED............................................................................................. 905 EL-95 MDTL ERROR EBB (DISCONNECTION IN REAR STEERING FREE SOLENOID)IS DISPLAYED............................................................................................. 906 EL-96 MDTL ERROR EBC (DISCONNECTION IN SERVICE BRAKE SOLENOID)IS DISPLAYED.................................................................................................. 907 EL-97 MDTL ERROR EBD (DISCONNECTION IN EXHAUST BRAKE SOLENOID)IS DISPLAYED.................................................................................................. 908 EL-98 MDTL ERROR EBF (DISCONNECTION IN PREHEATING [HEATER RELAY CIRCUIT])IS DISPLAYED....................................................................................... 909 EL-99 MDTL ERROR ECA (DISCONNECTION IN HEAD LAMP HI RELAY)IS DISPLAYED...................................................................................................... 910 EL-100 MDTL ERROR ECB (DISCONNECTION IN HEAD LAMP LO RELAY)IS DISPLAYED..................................................................................................... 911 EL-101 MDTL ERROR ECC (DISCONNECTION IN SIDE LAMP RELAY)IS DISPLAYED........................................................................................................ 912 EL-102 MDTL ERROR ECE (DISCONNECTION IN RIGHT TURN RELAY)IS DISPLAYED....................................................................................................... 913 EL-103 MDTL ERROR ECF (DISCONNECTION IN LEFT TURN RELAY)IS DISPLAYED........................................................................................................ 914 EL-104 MDTL ERROR ED0 (DISCONNECTION IN STEERING MODE SOLENOID A)IS DISPLAYED............................................................................................... 915 EL-105 MDTL ERROR ED1 (DISCONNECTION IN STEERING MODE SOLENOID C)IS DISPLAYED............................................................................................... 916 EL-106 MDTL ERROR ED2 (DISCONNECTION IN STEERING MODE SOLENOID B)IS DISPLAYED............................................................................................... 917 EL-107 MDTL ERROR ED3 (DISCONNECTION IN STEERING MODE SOLENOID D)IS DISPLAYED............................................................................................... 918 EL-108 MDTL ERROR ED4 (DISCONNECTION IN SWING PUMP MERGE SOLENOID)IS DISPLAYED.............................................................................................. 919 EL-109 MDTL ERROR ED7 (DISCONNECTION IN SUSPENSION LIFT SOLENOID)IS DISPLAYED............................................................................................... 920 EL-110 MDTL ERROR EE7 (OUTRIGGER CONTROL SIGNAL SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED.............................................................................. 921 EL-111 MDTL ERROR EE8 (OUTRIGGER CONTROL SIGNAL SHORT CIRCUITED WITH GROUND,DISCONNECTION)IS DISPLAYED...................................................................... 922 EL-112 MDTL ERROR EE9 (DISCONNECTION IN FUEL SENSOR)IS DISPLAYED............................................................................................................ 923 EL-113 MDTL ERROR EEB (ABNORMALITY IN REAR STEERING LOCK LIMIT SWITCH/FREE LIMIT SWITCH)IS DISPLAYED........................................................................ 924 EL-114 MDTL ERROR EEE (FAILURE OF BOTH SPEEDOMETER SENSORS)IS DISPLAYED..................................................................................................... 926 EL-115 MDTL ERROR EEF (MDT SPEEDOMETER SENSOR FAILURE)IS DISPLAYED.......................................................................................................... 928 EL-116 MDTL ERROR EF0 (SPECIAL STEERING FAILURE EMERGENCY STOP)IS DISPLAYED................................................................................................. 929 EL-117 MDTL ERROR EF1 (REVERSE STEERING FAILURE EMERGENCY STOP)IS DISPLAYED................................................................................................. 930 EL-118 MDTL ERROR EF2 (SPECIAL STEERING FAILURE)IS DISPLAYED................................................................................................................ 931 EL-119 MDTL ERROR EF3 (REVERSE STEERING FAILURE 1,NORMAL STEERING HELD)IS DISPLAYED......................................................................................... 932 EL-120 MDTL ERROR EF4 (REVERSE STEERING FAILURE 2,NORMAL STEERING HELD)IS DISPLAYED......................................................................................... 933 EL-121 MDTL ERROR EFE (ABNORMALITY IN RIGHT TURN RELAY)IS DISPLAYED......................................................................................................... 934 EL-122 MDTL ERROR EFF (ABNORMALITY IN LEFT TURN RELAY)IS DISPLAYED.......................................................................................................... 936 TROUBLESHOOTING OF MOMENT LIMITER CONTROLLER SYSTEM(EM MODE).................................................................................................................... 939 TABLE OF ERROR CODES AND TROUBLESHOOTING CODES.............................................................................................................................. 942 ACTION OF CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS....................................................................................................... 950 JUDGEMENT TABLE FOR MOMENT LIMITER CONTROLLER,AND HYDRAULIC AND MECHANICAL SYSTEMS.......................................................................................... 978 ELECTRICAL CIRCUIT DIAGRAM OF MOMENT LIMITER SYSTEM......................................................................................................................... 982 ELECTRICAL CIRCUIT DIAGRAM OF OUTRIGGER SYSTEM.............................................................................................................................. 983 EM- 1 OSS ERROR E00 (ABNORMALITY IN COMMUNICATION (CUT OFF) BETWEEN MOMENT LIMITER CONTROLLER AND MONITOR)IS DISPLAYED...................................................... 985 EM- 2 OSS ERROR E01 (PANEL SYSTEM ERROR)IS DISPLAYED........................................................................................................................ 986 EM- 3 OSS ERROR E02 (ABNORMALITY IN PANEL ROTARY SWITCH)IS DISPLAYED........................................................................................................ 986 EM- 4 OSS ERROR E10 (MOMENT LIMITER SYSTEM ERROR)IS DISPLAYED............................................................................................................... 986 EM- 5 OSS ERROR E20 (ABNORMALITY IN S-NET COMMUNICATION BETWEEN MOMENT LIMITER CONTROLLER AND MDT)IS DISPLAYED.............................................................. 987 EM- 6 OSS ERROR E21 (ABNORMALITY IN OUTRIGGER LENGTH SENSOR FL)IS DISPLAYED................................................................................................. 988 EM- 7 OSS ERROR E22 (ABNORMALITY IN OUTRIGGER LENGTH SENSOR FR)IS DISPLAYED................................................................................................. 990 EM- 8 OSS ERROR E23 (ABNORMALITY IN OUTRIGGER LENGTH SENSOR RL)IS DISPLAYED................................................................................................. 992 EM- 9 OSS ERROR E24 (ABNORMALITY IN OUTRIGGER LENGTH SENSOR RR)IS DISPLAYED................................................................................................. 994 EM-10 OSS ERROR E30 (ABNORMALITY IN COMMUNICATION (CUT OFF) BETWEEN MOMENT LIMITER CONTROLLER AND JIB TRANSMISSION MODULE)IS DISPLAYED...................................... 996 EM-11 OSS ERROR E31 (ABNORMALITY IN JIB TILT ANGLE SENSOR SYSTEM)IS DISPLAYED............................................................................................... 997 EM-12 OSS ERROR E41 (ABNORMALITY IN BOOM ANGLE SENSOR SYSTEM)IS DISPLAYED................................................................................................... 999 EM-13 OSS ERROR E43 (ABNORMALITY IN BOOM LENGTH SENSOR SYSTEM)IS DISPLAYED..................................................................................................1001 EM-14 OSS ERROR E44 (ABNORMALITY IN HOIST CYLINDER BOTTOM PRESSURE SENSOR SYSTEM)IS DISPLAYED...............................................................................1003 EM-15 OSS ERROR E45 (ABNORMALITY IN HOIST CYLINDER HEAD PRESSURE SENSOR SYSTEM)IS DISPLAYED.................................................................................1005 EM-16 OSS ERROR E46 (ABNORMALITY IN SWING ANGLE SENSOR)IS DISPLAYED.........................................................................................................1007 EM-17 OSS ERROR E48 (REVERSE ROTATION OF HOIST CYLINDER AXIS POWER)IS DISPLAYED.............................................................................................1009 EM-18 OSS ERROR E50 (MAIN UNLOAD SOLENOID SHORT CIRCUITED WITH GROUND)IS DISPLAYED..........................................................................................1010 EM-19 OSS ERROR E51 (PPC UNLOAD SOLENOID SHORT CIRCUITED WITH GROUND)IS DISPLAYED...........................................................................................1011 EM-20 OSS ERROR E52 (BOOM TELESCOPE SELECTOR SOLENOID SHORT CIRCUITED WITH GROUND)IS DISPLAYED..............................................................................1012 EM-21 OSS ERROR E53 (AUTOMATIC STOP CANCEL PROHIBITION RELAY SHORT CIRCUITED WITH GROUND)IS DISPLAYED.......................................................................1013 EM-26 OSS ERROR E58 (JIB AUTOMATIC EXTEND/STOW RELAY SHORT CIRCUITED WITH GROUND)IS DISPLAYED...............................................................................1014 EM-27 OSS ERROR E59 (JIB ROTATION PERMISSION RELAY SHORT CIRCUITED WITH GROUND)IS DISPLAYED.................................................................................1015 EM-30 OSS ERROR E5C (MOMENT LIMITER BUZZER SHORT CIRCUITED WITH GROUND)IS DISPLAYED.........................................................................................1016 EM-31 OSS ERROR E5D (EMERGENCY ALARM BUZZER SHORT CIRCUITED WITH GROUND)IS DISPLAYED........................................................................................1017 EM-32 OSS ERROR E68 (SENSOR 10V POWER SOURCE SHORT CIRCUITED WITH GROUND)IS DISPLAYED.......................................................................................1018 EM-33 OSS ERROR E6A (SENSOR 15V POWER SOURCE SHORT CIRCUITED WITH GROUND)IS DISPLAYED.......................................................................................1019 EM-34 OSS ERROR E70 (MAIN UNLOAD SOLENOID SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED....................................................................................1020 EM-35 OSS ERROR E71 (PPC UNLOAD SOLENOID SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED.....................................................................................1021 EM-36 OSS ERROR E72 (BOOM TELESCOPE SELECTOR SOLENOID SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED........................................................................1022 EM-37 OSS ERROR E73 (AUTOMATIC STOP CANCEL PROHIBITION RELAY SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED.................................................................1023 EM-41 OSS ERROR E78 (JIB AUTOMATIC EXTEND/STOW RELAY SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED.........................................................................1024 EM-42 OSS ERROR E79 (JIB ROTATION PERMISSION RELAY SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED...........................................................................1025 EM-43 OSS ERROR E88 (DISCONNECTION IN MAIN UNLOAD SOLENOID)IS DISPLAYED.....................................................................................................1026 EM-44 OSS ERROR E89 (DISCONNECTION IN PPC UNLOAD SOLENOID)IS DISPLAYED......................................................................................................1027 EM-45 OSS ERROR E8A (DISCONNECTION IN BOOM TELESCOPE SELECTOR SOLENOID)IS DISPLAYED.........................................................................................1028 EM-46 OSS ERROR E8B (DISCONNECTION IN AUTOMATIC STOP CANCEL PROHIBITION RELAY)IS DISPLAYED..................................................................................1029 EM-47 OSS ERROR EA0 (ABNORMALITY IN SWING OVER-FRONT LIMIT SWITCH)IS DISPLAYED..............................................................................................1030 EM-48 OSS ERROR EA1 (ABNORMALITY IN TOP BOOM STOW LIMIT SWITCH)IS DISPLAYED.................................................................................................1031 EM-49 OSS ERROR EA2 (ABNORMALITY IN BOOM SELECTOR SWITCH)IS DISPLAYED.......................................................................................................1032 EM-50 OSS ERROR EA3 (JIB LEFT LOCK PIN PROXIMITY SENSOR SHORT CIRCUITED WITH POWER SOURCE)IS DISPLAYED......................................................................1033 EM-52 OSS ERROR EA5 (ABNORMALITY IN PTO MODE SWITCH [TRAVEL MODE SWITHC INPUT]) IS DISPLAYED................................................................................1034 EM-53 OSS ERROR EA6 (H/X SELECTION DOESN'T MATCH)IS DISPLAYED...............................................................................................................1036 EM-54 OSS ERROR EA7 (SPECIFICATION SELECTION ROTARY SWITCH SETTING NOT AVAILABLE)IS DISPLAYED...............................................................................1036 EM-55 OSS ERROR EA8 (BOOM RAISE PPC PRESSURE SWITCH SHORT CIRCUITED WITH GROUND)IS DISPLAYED................................................................................1037 EM-56 OSS ERROR EA9 (BOOM LOWER PPC PRESSURE SWITCH SHORT CIRCUITED WITH GROUND)IS DISPLAYED................................................................................1038 EM-57 OSS ERROR EAA (BOOM EXTEND PPC PRESSURE SWITCH SHORT CIRCUITED WITH GROUND)IS DISPLAYED...............................................................................1039 EM-58 OSS ERROR EAB (BOOM RETRACT PPC PRESSURE SWITCH SHORT CIRCUITED WITH GROUND)IS DISPLAYED..............................................................................1040 EM-59 OSS ERROR EAC (JIB RAISE PPC PRESSURE SWITCH SHORT CIRCUITED WITH GROUND)IS DISPLAYED.................................................................................1041 EM-60 OSS ERROR EAD (JIB LOWER PPC PRESSURE SWITCH SHORT CIRCUITED WITH GROUND)IS DISPLAYED.................................................................................1042 EM-61 OSS ERROR EB0 (BOOM RAISE+LOWER PPC PRESSURE SWITCH INPUT SIMULTANEOUSLY)IS DISPLAYED.................................................................................1043 EM-62 OSS ERROR EB1 (BOOM EXTEND+RETRACT PPC PRESSURE SWITCH INPUT SIMULTANEOUSLY)IS DISPLAYED..............................................................................1045 EM-63 OSS ERROR EB2 (JIB RAISE+LOWER PPC PRESSURE SWITCH INPUT SIMULTANEOUSLY)IS DISPLAYED..................................................................................1047 EM-64 OSS ERROR EB3 (SWING LEFT+RIGHT PPC PRESSURE SWITCH INPUT SIMULTANEOUSLY)IS DISPLAYED.................................................................................1049 EM-65 OSS ERROR EB4 (MAIN WINCH WIND IN+WIND OUT PPC PRESSURE SWITCH INPUT SIMULTANEOUSLY)IS DISPLAYED......................................................................1051 EM-66 OSS ERROR EB5 (AUXILIARY WINCH WIND IN+WIND OUT PPC PRESSURE SWITCH INPUT SIMULTANEOUSLY)IS DISPLAYED.................................................................1053 EM-101 ABNORMALITY IN MOMENT LIMITER CONTROLLER POWER SOURCE SYSTEM.........................................................................................................1055 EM-102 ABNORMALITY IN MOMENT LIMITER PANEL POWER SOURCE SYSTEM..............................................................................................................1058 EM-103 ABNORMALITY IN JIB COMMUNICATION MODULE POWER SOURCE SYSTEM..........................................................................................................1059 EM-104 DOES NOT ENTER WORKING MODE(WORK EQUIPMENT AND WINCH DO NOT WORK)....................................................................................................1061 EM-106 ABNORMALITY IN WINCH OVERWIND LIMITER SWITCH SYSTEM..................................................................................................................1063 EM-106-1 LIFTING CAPACITY IS LIMITED(ABNORMALITY IN TOP BOOM STOW LIMIT SWITCH).............................................................................................1071 EM-106-2 BOOM TELESCOPE CANNOT BE SELECTED(TOP OR 2ND)(USUAL OPERATIONS ARE NORMAL)(DEFECTIVE BOOM SELECTOR SWITCH SYSTEM)..................................................1072 EM-106-3 ABNORMALITY IN SWING OVER-FRONT LIMIT SWITCH.......................................................................................................................1073 EM-106-4 ABNORMALITY IN SWING ANGLE SENSOR (2) SYSTEM.......................................................................................................................1074 EM-107 MAIN WINCH DOES NOT SWITCH TO FREE-FALL OR REMAINS IN FREE-FALL CONDITION(ABNORMALITY IN MAIN WINCH FREE-FALL INTERLOCK SOLENOID SYSTEM).............................1075 EM-108 AUXILIARY WINCH DOES NOT SWITCH TO FREE-FALL OR REMAINS IN FREE-FALL CONDITION(ABNORMALITY IN AUXILIARY WINCH FREE-FALL INTERLOCK SOLENOID SYSTEM)...................1077 EM-109 ABNORMALITY IN JIB LEFT LOCK PIN PROXIMITY SENSOR SYSTEM.............................................................................................................1079 EM-110 ABNORMALITY IN LEFT LOCK PIN COMPLETION INDICATOR SYSTEM.............................................................................................................1081 EM-111 ABNORMALITY IN JIB CABLE CONNECTION SIGNAL SYSTEM....................................................................................................................1082 EM-112 ABNORMALITY IN JIB AUTOMATIC EXTEND/STOW RELAY SYSTEM................................................................................................................1083 EM-113 ABNORMALITY IN JIB ROTATION PERMISSION RELAY SYSTEM..................................................................................................................1084 EM-114 ABNORMALITY IN JIB SELECTOR SOLENOID SYSTEM..........................................................................................................................1085 EM-115 ABNORMALITY IN JIB LEFT LOCK PIN SOLENOID(EXTEND) SYSTEM.............................................................................................................1089 EM-116 ABNORMALITY IN JIB LEFT LOCK PIN SOLENOID(STOW) SYSTEM...............................................................................................................1096 EM-117 ABNORMALITY IN JIB STOW DETECTION SENSOR SYSTEM......................................................................................................................1104 EM-118 ABNORMALITY IN JIB STOW COMPLETION INDICATOR SYSTEM..................................................................................................................1107 EM-119 ABNORMALITY IN JIB ROTATION SOLENOID(EXTEND) SYSTEM..................................................................................................................1109 EM-120 ABNORMALITY IN JIB ROTATION SOLENOID(STOW) SYSTEM....................................................................................................................1116 EM-121 ABNORMALITY IN JIB RIGHT LOCK PIN SOLENOID(EXTEND) SYSTEM............................................................................................................1124 EM-122 ABNORMALITY IN JIB RIGHT LOCK PIN SOLENOID(STOW) SYSTEM..............................................................................................................1131 EM-123 ABNORMALITY IN SWING BRAKE SOLENOID SYSTEM...........................................................................................................................1139 EM-124 ABNORMALITY IN SWING FREE SOLENOID SYSTEM............................................................................................................................1141 EM-125 ABNORMALITY IN MAIN WINCH DRUM SPEED SIGNAL(ABNORMALITY IN MAIN WINCH DRUM SPEED SENSOR SYSTEM)......................................................................1143 EM-126 ABNORMALITY IN AUXILIARY WINCH DRUM SPEED DISPLAY OR ABNORMALITY IN AUXILIARY WINCH SPEED BUZZER.....................................................................1144 EM-127 ABNORMALITY IN MAIN WINCH BUZZER SYSTEM..............................................................................................................................1145 EM-128 ABNORMALITY IN AUXILIARY WINCH BUZZER SYSTEM.........................................................................................................................1147 EM-129 ABNORMALITY IN AUTOMATIC STOP CANCEL PROHIBITION RELAY SYSTEM........................................................................................................1149 EM-130 ABNORMALITY IN AUTOMATIC STOP CANCEL SIGNAL SYSTEM...................................................................................................................1153 EM-131 ABNORMALITY IN PEDAL OPERATION SELECTOR SOLENOID SYSTEM..............................................................................................................1154 EM-132 ABNORMALITY IN ACCUMULATOR PRESSURE SWITCH SYSTEM....................................................................................................................1158 EM-133 ABNORMALITY IN MAIN WINCH WIND IN PPC PRESSURE SWITCH SYSTEM.........................................................................................................1160 EM-134 ABNORMALITY IN MAIN WINCH WIND OUT PPC PRESSURE SWITCH SYSTEM........................................................................................................1161 EM-135 ABNORMALITY IN AUXILIARY WINCH WIND IN PPC PRESSURE SWITCH SYSTEM....................................................................................................1162 EM-136 ABNORMALITY IN AUXILIARY WINCH WIND OUT PPC PRESSURE SWITCH SYSTEM...................................................................................................1163 EM-137 ABNORMALITY IN SWING LEFT PPC PRESSURE SWITCH SYSTEM.................................................................................................................1164 EM-138 ABNORMALITY IN SWING RIGHT PPC PRESSURE SWITCH SYSTEM................................................................................................................1165 EM-139 ABNORMALITY IN MOMENT LIMITER BUZZER SYSTEM..........................................................................................................................1166 EM-140 ABNORMALITY IN EMERGENCY ALARM BUZZER SYSTEM.........................................................................................................................1167 EM-201 ABNORMALITY IN OUTRIGGER PANEL POWER SOURCE SYSTEM...................................................................................................................1168 EM-202 ABNORMALITY IN OUTRIGGER POWER SOURCE RELAY(OUTRIGGER POWER SOURCE/BOTTOM PANEL POWER SOURCE)SYSTEM..................................................................1170 EM-203 ABNORMALITY IN OUTRIGGER LENGTH SENSOR POWER SOURCE SYSTEM...........................................................................................................1173 EM-204 ABNORMALITY IN OUTRIGGER MODE SYSTEM.................................................................................................................................1174 EM-205 DEFECTIVE OPERATION OF TOP OUTRIGGER EXTEND/STOW SWITCH(EXTEND) SYSTEM...............................................................................................1175 EM-206 DEFECTIVE OPERATION OF TOP OUTRIGGER EXTEND/STOW SWITCH(STOW) SYSTEM.................................................................................................1177 EM-207 DEFECTIVE OPERATION OF TOP OUTRIGGER SLIDE/JACK SWITCH(SLIDE) SYSTEM.................................................................................................1179 EM-208 DEFECTIVE OPERATION OF TOP OUTRIGGER SLIDE/JACK SWITCH(JACK) SYSTEM..................................................................................................1181 EM-209 DEFECTIVE OPERATION OF TOP OUTRIGGER ALL SWITCH SYSTEM...............................................................................................................1183 EM-210 DEFECTIVE OPERATION OF TOP OUTRIGGER FL SWITCH SYSTEM................................................................................................................1185 EM-211 DEFECTIVE OPERATION OF TOP OUTRIGGER FR SWITCH SYSTEM................................................................................................................1187 EM-212 DEFECTIVE OPERATION OF TOP OUTRIGGER RL SWITCH SYSTEM................................................................................................................1189 EM-213 DEFECTIVE OPERATION OF TOP OUTRIGGER RR SWITCH SYSTEM................................................................................................................1191 EM-214 DEFECTIVE OPERATION OF BOTTOM OUTRIGGER ALL SWITCH SYSTEM............................................................................................................1193 EM-215 DEFECTIVE OPERATION OF BOTTOM OUTRIGGER CONTROL PANEL(RL JACK) SYSTEM................................................................................................1195 EM-216 DEFECTIVE OPERATION OF BOTTOM OUTRIGGER CONTROL PANEL(FL JACK) SYSTEM................................................................................................1197 EM-217 DEFECTIVE OPERATION OF BOTTOM OUTRIGGER CONTROL PANEL(RR JACK) SYSTEM................................................................................................1199 EM-218 DEFECTIVE OPERATION OF BOTTOM OUTRIGGER CONTROL PANEL(FR JACK) SYSTEM................................................................................................1201 EM-219 DEFECTIVE OPERATION OF BOTTOM OUTRIGGER CONTROL PANEL(RL SLIDE) SYSTEM...............................................................................................1203 EM-220 DEFECTIVE OPERATION OF BOTTOM OUTRIGGER CONTROL PANEL(FL SLIDE) SYSTEM...............................................................................................1204 EM-221 DEFECTIVE OPERATION OF BOTTOM OUTRIGGER CONTROL PANEL(RR SLIDE) SYSTEM...............................................................................................1205 EM-222 DEFECTIVE OPERATION OF BOTTOM OUTRIGGER CONTROL PANEL(FR SLIDE) SYSTEM...............................................................................................1206 EM-223 ABNORMALITY IN IDLE-UP SWITCH SYSTEM.................................................................................................................................1207 EM-224 ABNORMALITY IN SWING PUMP MERGE SOLENOID SYSTEM......................................................................................................................1209 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM(ET MODE)......................................................................................................................1212 TABLE OF ERROR CODES AND TROUBLESHOOTING CODES..............................................................................................................................1213 ACTION OF CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS.......................................................................................................1221 JUDGEMENT TABLE FOR TRANSMISSION SYSTEM.....................................................................................................................................1239 TRANSMISSION CONTROLLER LED DISPLAY.........................................................................................................................................1241 TRANSMISSION CONTROLLER SYSTEM ELECTRICAL CIRCUIT DIAGRAM...................................................................................................................1243 ET- 1 ATM ERROR E11 (DISCONNECTION IN TACHOMETER SENSOR) IS DISPLAYED.......................................................................................................1246 ET- 2 ATM ERROR E12 (DISCONNECTION IN SPEED SENSOR 1) IS DISPLAYED..........................................................................................................1247 ET- 3 ATM ERROR E13 (DISCONNECTION IN SPEED SENSOR 2) IS DISPLAYED..........................................................................................................1248 ET- 4 ATM ERROR E14 (DISCONNECTION IN ACCELERATOR POTENTIOMETER) IS DISPLAYED...............................................................................................1249 ET- 5 ATM ERROR E17 (DISCONNECTION IN SHIFT LEVER) IS DISPLAYED.............................................................................................................1250 ET- 6 ATM ERROR E18 (DISCONNECTION IN F/R SIGNAL FOR INTERLOCK) IS DISPLAYED................................................................................................1251 ET- 7 ATM ERROR E19 (ABNORMALITY IN INPUT FOR TRANSMISSION SOLENOID POWER SOURCE MONITOR ) IS DISPLAYED.....................................................................1252 ET- 8 ATM ERROR E24 (ACCELERATOR POTENTIOMETER SHORT CIRCUITED WITH GROUND) IS DISPLAYED....................................................................................1253 ET- 9 ATM ERROR E25 (ABNORMALITY IN EMERGENCY GEAR SHIFT SWITCH OR ABNORMALITY IN PTO SWITCH) IS DISPLAYED..................................................................1254 ET-10 ATM ERROR E32 (ABNORMALITY IN SPEED SENSOR 1) IS DISPLAYED............................................................................................................1255 ET-11 ATM ERROR E33 (ABNORMALITY IN SPEED SENSOR 2) IS DISPLAYED............................................................................................................1256 ET-12 ATM ERROR E35 (ABNORMALITY IN INTERLOCK SIGNAL F/R [MDT AT OTHER THAN N WITH INTERLOCK SIGNAL N]) IS DISPLAYED........................................................1257 ET-13 ATM ERROR E37 (ABNORMALITY IN SHIFT LEVER(2 OR MORE SIGNALS ON)) IS DISPLAYED.........................................................................................1258 ET-14 ATM ERROR E38 (INTERLOCK F+R SIGNALS INPUT SIMULTANEOUSLY) IS DISPLAYED...............................................................................................1259 ET-15 ATM ERROR E39 (INTERLOCK SIGNAL F/R BUT LEVER SIGNAL N IS INPUT[MDT AT N]) IS DISPLAYED...............................................................................1260 ET-16 ATM ERROR E3F (ABNORMALITY IN S-NET) IS DISPLAYED.....................................................................................................................1261 ET-17 ATM ERROR E53 (OVERRUN) IS DISPLAYED..................................................................................................................................1262 ET-18 ATM ERROR E55 (DROP IN BATTERY VOLTAGE) IS DISPLAYED..................................................................................................................1262 ET-19 ATM ERROR E5A (SPECIAL STEERING SYSTEM SHORT CIRCUITED WITH GROUND) IS DISPLAYED......................................................................................1263 ET-20 ATM ERROR E5B (DISCONNECTION IN SPECIAL STEERING SYSTEM) IS DISPLAYED.................................................................................................1264 ET-21 ATM ERROR E5C (REVERSE STEERING SYSTEM SHORT CIRCUITED WITH GROUND) IS DISPLAYED......................................................................................1265 ET-22 ATM ERROR E5D (DISCONNECTION IN REVERSE STEERING SYSTEM) IS DISPLAYED.................................................................................................1266 ET-23 ATM ERROR E70 (DISCONNECTION IN R SOLENOID [ECMV] SYSTEM) IS DISPLAYED................................................................................................1267 ET-24 ATM ERROR E71 (DISCONNECTION IN F2 SOLENOID [ECMV] SYSTEM) IS DISPLAYED...............................................................................................1268 ET-25 ATM ERROR E72 (DISCONNECTION IN F1 SOLENOID [ECMV] SYSTEM) IS DISPLAYED...............................................................................................1269 ET-26 ATM ERROR E73 (DISCONNECTION IN F3 SOLENOID [ECMV] SYSTEM) IS DISPLAYED...............................................................................................1270 ET-27 ATM ERROR E74 (DISCONNECTION IN LOCK-UP SOLENOID [ECMV] SYSTEM) IS DISPLAYED..........................................................................................1271 ET-28 ATM ERROR E78 (DISCONNECTION IN LO SOLENOID SYSTEM) IS DISPLAYED......................................................................................................1272 ET-29 ATM ERROR E79 (DISCONNECTION IN 4WD SOLENOID SYSTEM) IS DISPLAYED.....................................................................................................1273 ET-30 ATM ERROR E7B (DISCONNECTION IN REVERSE STEERING COMPENSATION RELAY SYSTEM) IS DISPLAYED..............................................................................1274 ET-31 ATM ERROR E7C (DISCONNECTION IN F2,R SOLENOID [ECMV] CUT RELAY SYSTEM) IS DISPLAYED...................................................................................1275 ET-32 ATM ERROR E7D (DISCONNECTION IN BACK-UP LAMP RELAY) IS DISPLAYED......................................................................................................1276 ET-33 ATM ERROR E7E (DISCONNECTION IN F1,F3 SOLENOID [ECMV] CUT RELAY SYSTEM) IS DISPLAYED..................................................................................1277 ET-34 ATM ERROR E7F (DISCONNECTION IN SPECIAL STEERING RELAY SYSTEM) IS DISPLAYED...........................................................................................1278 ET-35 ATM ERROR E80 (R SOLENOID [ECMV] SYSTEM SHORT CIRCUITED WITH GROUND) IS DISPLAYED.....................................................................................1279 ET-36 ATM ERROR E81 (F2 SOLENOID [ECMV] SYSTEM SHORT CIRCUITED WITH GROUND) IS DISPLAYED....................................................................................1280 ET-37 ATM ERROR E82 (F1 SOLENOID [ECMV] SYSTEM SHORT CIRCUITED WITH GROUND) IS DISPLAYED....................................................................................1281 ET-38 ATM ERROR E83 (F3 SOLENOID [ECMV] SYSTEM SHORT CIRCUITED WITH GROUND) IS DISPLAYED....................................................................................1282 ET-39 ATM ERROR E84 (LOCK-UP SOLENOID [ECMV] SYSTEM SHORT CIRCUITED WITH GROUND) IS DISPLAYED...............................................................................1283 ET-40 ATM ERROR E88 (LO SOLENOID SYSTEM SHORT CIRCUITED WITH GROUND) IS DISPLAYED...........................................................................................1284 ET-41 ATM ERROR E89 (4WD SOLENOID SYSTEM SHORT CIRCUITED WITH GROUND) IS DISPLAYED..........................................................................................1285 ET-42 ATM ERROR E8B (REVERSE STEERING RELAY SYSTEM SHORT CIRCUITED WITH GROUND) IS DISPLAYED................................................................................1286 ET-43 ATM ERROR E8C (F2,R SOLENOID [ECMV] CUT RELAY SYSTEM SHORT CIRCUITED WITH GROUND) IS DISPLAYED........................................................................1287 ET-44 ATM ERROR E8D (BACK-UP LAMP RELAY SYSTEM SHORT CIRCUITED WITH GROUND) IS DISPLAYED....................................................................................1288 ET-45 ATM ERROR E8E (F1,F3 SOLENOID [ECMV] CUT RELAY SYSTEM SHORT CIRCUITED WITH GROUND) IS DISPLAYED.......................................................................1289 ET-46 ATM ERROR E8F (SPECIAL STEERING RELAY SYSTEM SHORT CIRCUITED WITH GROUND) IS DISPLAYED................................................................................1290 ET-47 ATM ERROR E90,E91 (R OR F2 SOLENOID [ECMV] SHORT CIRCUITED WITH POWER SOURCE) IS DISPLAYED............................................................................1291 ET-48 ATM ERROR E92,E93 (F3 OR F1 SOLENOID [ECMV] SHORT CIRCUITED WITH POWER SOURCE) IS DISPLAYED...........................................................................1292 ET-49 ATM ERROR E94 (LOCK-UP SOLENOID [ECMV] SHORT CIRCUITED WITH POWER SOURCE) IS DISPLAYED................................................................................1293 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS(H MODE).....................................................................................................................1294 TABLE OF FAILURE MODES AND CAUSES(HYDRAULIC AND MECHANICAL SYSTEMS).........................................................................................................1295 H-1 BOOM AND WINCH DO NOT MOVE(INCLUDING CASES WHERE PTO CLUTCH DOES NOT ENGAGE)............................................................................................1297 H-2 BOOM CANNOT BE RAISED OR LOWERED,OR SPEED IS SLOW.......................................................................................................................1298 H-3 BOOM CANNOT BE EXTENDED OR RETRACTED,OR SPEED IS SLOW...................................................................................................................1300 H-4 WINCH CANNOT BE WOUND IN OR WOUND OUT,OR SPEED IS SLOW..................................................................................................................1302 H-5 WINCH MOVES INTERMITTENTLY(THERE IS HUNTING)............................................................................................................................1304 H-6 JIB CANNOT BE RAISED,LOWERED,EXTENDED,OR STOWED(POWER TILT MACHINE).....................................................................................................1306 H-7 UPPER STRUCTURE CANNOT BE SWUNG OR SWING SPEED IS SLOW..................................................................................................................1310 H-8 OUTRIGGERS CANNOT BE EXTENDED OR STOWED.................................................................................................................................1312 H-9 EXCESSIVE HYDRAULIC DRIFT...............................................................................................................................................1313 H-101 MACHINE DOES NOT MOVE OFF.............................................................................................................................................1314 H-102 MACHINE DOES NOT ACCELERATE OR DOES NOT DECELERATE....................................................................................................................1315 H-103 TRAVEL SPEED IS SLOW OR LACKS POWER...................................................................................................................................1316 H-104 TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE OR CANNOT BE DISENGAGED(ENGINE STALLS WHEN MACHINE IS STOPPED OR MOVES OFF)..................................................1318 H-105 EXCESSIVE TIME LAG WHEN MOVING OFF(SHIFTING GEAR),OR SHIFT UP IS SLOW.................................................................................................1319 H-106 TORQUE CONVERTER OIL TEMPERATURE BECOMES HIGH.........................................................................................................................1320 H-107 BRAKE CANNOT BE APPLIED(BRAKING EFFECT IS POOR),PULLS TO ONE SIDE,OR CANNOT BE RELEASED(DRAGS)........................................................................1322 H-108 EXHAUST BRAKE CANNOT BE APPLIED OR CANNOT BE RELEASED.................................................................................................................1324 H-109 AIR PRESSURE DOES NOT RISE OR IS TOO LOW..............................................................................................................................1325 H-110 CANNOT SWITCH BETWEEN 2-WHEEL DRIVE AND 4-WHEEL DRIVE,OR BETWEEN HI AND LO............................................................................................1326 H-111 STEERING MODE CANNOT BE SWITCHED......................................................................................................................................1326 H-112 WHEELS DO NOT MOVE WHEN STEERING WHEEL IS TURNED(STEERING DOES NOT TURN OR IS DIFFICULT TO TURN)......................................................................1328 H-113 REAR STEERING IS NOT LOCKED OR IS NOT RELEASED........................................................................................................................1330 H-114 SUSPENSION CANNOT BE LOCKED OR CANNOT BE SET FREE.....................................................................................................................1331 H-115 SUSPENSION LIFT CANNOT BE USED........................................................................................................................................1332 TROUBLESHOOTING OF MONITOR PANEL SYSTEM(M MODE).................................................................................................................................1333 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE MONITOR SYSTEM........................................................................................................................1334 M- 1 ABNORMALITY IN AIR PRESSURE GAUGE......................................................................................................................................1336 M- 2 AIR PRESSURE GOES DOWN BUT MONITOR LAMP DOES NOT LIGHT UP..............................................................................................................1339 M- 3 EXHAUST BRAKE LAMP DOES NOT LIGHT UP...................................................................................................................................1340 M- 4 PREHEATING MONITOR LAMP DOES NOT LIGHT UP..............................................................................................................................1341 M- 5 CHARGE LAMP DOES NOT GO OUT............................................................................................................................................1342 M- 6 ENGINE OIL PRESSURE LAMP DOES NOT GO OUT...............................................................................................................................1343 M- 7 AUXILIARY(SERVICE)BRAKE LAMP DOES NOT LIGHT UP.........................................................................................................................1344 M- 8 DEFECTIVE LIGHTING UP OF PARKING BRAKE LAMP............................................................................................................................1345 M- 9 ABNORMAL DISPLAY OF FUEL GAUGE.........................................................................................................................................1347 M-10 ABNORMAL DISPLAY OF WATER TEMPERATURE GAUGE............................................................................................................................1349 M-11 TACHOMETER DOES NOT WORK...............................................................................................................................................1351 M-12 SPEEDOMETER DOES NOT WORK..............................................................................................................................................1353 M-13 TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP LIGHTS UP................................................................................................................1355 M-14 BRAKE FLUID LEVEL CAUTION LAMP LIGHTS UP...............................................................................................................................1356 M-15 HOURMETER DOES NOT WORK................................................................................................................................................1357 TROUBLESHOOTING OF ELECTRICAL SYSTEM(E MODE)....................................................................................................................................1358 ELECTRICAL CIRCUIT DIAGRAM OF POWER SOURCE,STARTING,CHARGING,AND PREHEATING SYSTEMS.........................................................................................1361 PTO SOLENOID SYSTEM CIRCUIT DIAGRAM.........................................................................................................................................1363 ELECTRICAL CIRCUIT DIAGRAM OF BRAKE SYSTEM..................................................................................................................................1364 ELECTRICAL CIRCUIT DIAGRAM OF STEERING SYSTEM...............................................................................................................................1365 ELECTRICAL CIRCUIT DIAGRAM OF SUSPENSION SYSTEM.............................................................................................................................1367 ELECTRICAL CIRCUIT DIAGRAM OF TURN SIGNAL AND SWING FLASHER SYSTEMS.........................................................................................................1368 ELECTRICAL CIRCUIT DIAGRAM OF LAMP,HORN,AND GREASE SYSTEMS..................................................................................................................1370 ELECTRICAL CIRCUIT DIAGRAM OF NIGHT LIGHTING SYSTEM.........................................................................................................................1372 E- 1 MAIN POWER SOURCE IS NOT SUPPLIED(REACHES INLET PORT OF FUSE BOX)......................................................................................................1374 a) POWER SOURCE DIRECT FROM BATTERY(NSW)................................................................................................................................1374 b) POWER SOURCE(SW) IS NOT SUPPLIED WHEN STARTING SWITCH IS TURNED ON...................................................................................................1375 E- 2 ENGINE DOES NOT START WHEN STARTING SWITCH IS TURNED TO START..........................................................................................................1378 a) STARTING MOTOR DOES NOT TURN.........................................................................................................................................1378 b) STARTING MOTOR TURNS (ENGINE STOP MOTOR SYSTEM)......................................................................................................................1381 E- 3 ENGINE DOES NOT STOP...................................................................................................................................................1383 E- 4 PREHEATING DOES NOT WORK...............................................................................................................................................1384 E- 5 ABNORMALITY IN PTO SOLENOID SYSTEM.....................................................................................................................................1386 a) DOES NOT SWITCH TO PTO (OPERATION) MODE (ENGINE SPEED DOES NOT GO DOWN)(DISCONNECTION)...............................................................................1386 b) PTO (OPERATION)MODE IS NOT SWITCHED OFF (SHORT CIRCUIT WITH POWER SOURCE)............................................................................................1386 E- 6 PARKING BRAKE CANNOT BE RELEASED OR CANNOT BE APPLIED..................................................................................................................1388 a) PARKING BRAKE CANNOT BE RELEASED(DISCONNECTION)......................................................................................................................1388 b) PARKING BRAKE CANNOT BE APPLIED(SHORT CIRCUIT WITH POWER SOURCE).....................................................................................................1388 E- 7 ABNORMALITY IN REAR STEERING CENTER DETECTION LIMIT SWITCH SYSTEM......................................................................................................1390 a) ALWAYS DETECTS POSITION OTHER THAN REAR CENTER (DISCONNECTION).......................................................................................................1390 b) ALWAYS DETECTS REAR STEERING CENTER (SHORT CIRCUIT WITH CHASSIS GROUND)..............................................................................................1390 E- 8 ABNORMALITY IN SUSPENSION LOCK SYSTEM..................................................................................................................................1391 a) SUSPENSION LOCK CANNOT BE APPLIED (SHORT CIRCUIT WITH POWER SOURCE)..................................................................................................1391 b) SUSPENSION LOCK CANNOT BE RELEASED (DISCONNECTION)...................................................................................................................1391 c) ANTI-NOSEDIVE FUNCTION DOES NOT WORK (ANTI-NOSEDIVE RELAY SYSTEM)....................................................................................................1392 E- 9 SWING FLASHER DOES NOT FLASH (DISCONNECTION)...........................................................................................................................1393 E-10 ABNORMALITY IN EMERGENCY ALARM BUZZER SYSTEM...........................................................................................................................1394 a) EMERGENCY ALARM BUZZER DOES NOT SOUND (DISCONNECTION)................................................................................................................1394 b) EMERGENCY ALARM BUZZER DOES NOT STOP (SHORT CIRCUIT WITH POWER SOURCE)...............................................................................................1394 E-11 ABNORMALITY IN MONITOR CENTRAL BUZZER SYSTEM...........................................................................................................................1395 a) MONITOR CENTRAL BUZZER DOES NOT SOUND (DISCONNECTION)................................................................................................................1395 b) MONITOR CENTRAL BUZZER DOES NOT STOP (SHORT CIRCUIT WITH POWER SOURCE)...............................................................................................1395 E-12 ABNORMALITY IN MOMENT LIMITER BUZZER SYSTEM............................................................................................................................1396 a) MOMENT LIMITER BUZZER DOES NOT SOUND (DISCONNECTION).................................................................................................................1396 b) MOMENT LIMITER BUZZER DOES NOT STOP (SHORT CIRCUIT WITH POWER SOURCE)................................................................................................1396 E-13 HORN DOES NOT SOUND OR DOES NOT STOP...................................................................................................................................1397 a) HORN DOES NOT SOUND (DISCONNECTION)..................................................................................................................................1397 b) HORN DOES NOT STOP (SHORT CIRCUIT WITH POWER SOURCE).................................................................................................................1398 E-14 WORKING LAMPS DO NOT LIGHT UP..........................................................................................................................................1399 a) NO WORKING LAMP LIGHTS UP............................................................................................................................................1399 b) WORKING LAMP ON TOP OF CAB DOES NOT LIGHT UP.........................................................................................................................1399 c) BOOM WORKING LAMP,WORKING LAMP DO NOT LIGHT UP.......................................................................................................................1400 E-15 HEAD LAMP HI BEAM DOES NOT LIGHT UP OR DOES NOT GO OUT.................................................................................................................1401 a) HEAD LAMP HI BEAM DOES NOT LIGHT UP (DISCONNECTION)..................................................................................................................1401 b) HEAD LAMP HI BEAM DOES NOT GO OUT (SHORT CIRCUIT WITH POWER SOURCE)..................................................................................................1402 E-16 HEAD LAMP LO BEAM DOES NOT LIGHT UP OR DOES NOT GO OUT.................................................................................................................1403 a) HEAD LAMP LO BEAM DOES NOT LIGHT UP (DISCONNECTION)..................................................................................................................1403 b) HEAD LAMP HI BEAM DOES NOT GO OUT (SHORT CIRCUIT WITH POWER SOURCE)..................................................................................................1404 E-17 BACK-UP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT......................................................................................................................1405 a) BACK-UP LAMP DOES NOT LIGHT UP (DISCONNECTION).......................................................................................................................1405 b) BACK-UP LAMP DOES NOT GO OUT (SHORT CIRCUIT WITH POWER SOURCE).......................................................................................................1405 E-18 STOP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT.........................................................................................................................1406 a) STOP LAMP DOES NOT LIGHT UP (DISCONNECTION)..........................................................................................................................1406 b) STOP LAMP DOES NOT GO OUT (SHORT CIRCUIT WITH POWER SOURCE)..........................................................................................................1406 E-19 SIDE LAMP,TAIL LAMP,LICENSE LAMP DO NOT LIGHT UP OR DO NOT GO OUT......................................................................................................1407 a) SIDE LAMP,TAIL LAMP,LICENSE LAMP DO NOT LIGHT UP (DISCONNECTION).....................................................................................................1407 b) SIDE LAMP,TAIL LAMP,LICENSE LAMP DO NOT TO OUT(SHORT CIRCUIT WITH POWER SOURCE)......................................................................................1408 E-20 ROOM LAMP DOES NOT LIGHT UP............................................................................................................................................1409 E-21 STEP LAMP DOES NOT LIGHT UP............................................................................................................................................1410 E-22 ABNORMALITY IN TACHOGRAPH SYSTEM.......................................................................................................................................1411 a) TACHOGRAPH DOES NOT WORK (SPEED INDICATOR DOES NOT MOVE).............................................................................................................1411 b) CANNOT BE PRINTED OUT ON TACHOGRAPH PRINT SHEET......................................................................................................................1411 E-23 CENTRALIZED GREASING CANNOT BE CARRIED OUT.............................................................................................................................1412 E-24 GREASING COMPLETION LAMP DOES NOT LIGHT UP.............................................................................................................................1412 E-25 FRONT WIPER,FRONT WINDOW WASHER DO NOT WORK............................................................................................................................1414 a) FRONT WIPER (HI,LO SPEED) DOES NOT WORK..............................................................................................................................1414 b) FRONT WIPER (INTERMITTENT) DOES NOT WORK.............................................................................................................................1414 c) FRONT WINDOW WASHER DOES NOT WORK....................................................................................................................................1415 E-26 ROOF WIPER,ROOF WINDOW WASHER DO NOT WORK..............................................................................................................................1416 a) ROOF WIPER DOES NOT WORK.............................................................................................................................................1416 b) ROOF WIPER (INTERMITTENT) DOES NOT WORK..............................................................................................................................1416 c) ROOF WINDOW WASHER DOES NOT WORK.....................................................................................................................................1417 E-27 NIGHT LIGHTING DOES NOT LIGHT UP (OUTRIGGER TELESCOPE SWITCH LIGHTING DOES NOT LIGHT UP)...............................................................................1418 E-51 DEFECTIVE AIR CONDITIONER..............................................................................................................................................1419 TROUBLESHOOTING CHART FOR AIR CONDITIONER SYSTEM........................................................................................................................1419 E-51 a) AIR CONDITIONER DOES NOT WORK AT ALL........................................................................................................................1420 a)-(1)DOES NOT WORK AT ALL,CONTROL PANEL LEDS DO NOT LIGHT UP...................................................................................................1420 a)-(2)TROUBLESHOOTING OF COOLING CIRCUIT........................................................................................................................1421 a)-(3)IMPOSSIBLE TO ADJUST AIR TEMPERATURE......................................................................................................................1422 a)-(4)COMPRESSOR CLUTCH DOES NOT COME ON........................................................................................................................1423 E-51 b) DEFECTIVE COOLING...........................................................................................................................................1424 b)-(1)CONDENSER FAN MOTOR DOES NOT TURN.........................................................................................................................1424 b)-(2)TROUBLESHOOTING OF HOT WATER CIRCUIT......................................................................................................................1425 E-51 c) DEFECTIVE HEATING...........................................................................................................................................1426 E-51 d) NO BREEZE COMES FROM VENT...................................................................................................................................1427 E-51 e) IMPOSSIBLE TO ADJUST WIND FORCE.............................................................................................................................1429 E-51 f) IMPOSSIBLE TO ADJUST AIR TEMPERATURE........................................................................................................................1430 E-51 g) IMPOSSIBLE TO SWITCH VENTS..................................................................................................................................1431 E-51 h) IMPOSSIBLE TO SWITCH FRESH/RECIRC...........................................................................................................................1432 E-51 i) ABNORMAL NOISE..............................................................................................................................................1433 E-51 j) WATER LEAKS FROM AIR CONDITIONER UNIT.......................................................................................................................1434 ADDITIONAL INFORMATION FOR TROUBLESHOOTING OF AIR CONDITIONER...........................................................................................................1435 30 DISASSEMBLY AND ASSEMBLY.............................................................................................................................................................1437 METHOD OF USING MANUAL..............................................................................................................................................................1441 PRECAUTIONS WHEN CARRYING OUT OPERATION.............................................................................................................................................1442 SPECIAL TOOL LIST...................................................................................................................................................................1444 SKETCHES OF SPECIAL TOOLS...........................................................................................................................................................1449 REMOVAL AND INSTALLATION........................................................................................................................................................1452 ALTERNATOR..........................................................................................................................................................................1453 REMOVAL AND INSTALLATION........................................................................................................................................................1453 ENGINE OIL COOLER...................................................................................................................................................................1454 REMOVAL AND INSTALLATION........................................................................................................................................................1454 FUEL INJECTION PUMP.................................................................................................................................................................1455 REMOVAL.........................................................................................................................................................................1455 INSTALLATION....................................................................................................................................................................1456 WATER PUMP..........................................................................................................................................................................1457 REMOVAL AND INSTALLATION........................................................................................................................................................1457 THERMOSTAT..........................................................................................................................................................................1458 REMOVAL AND INSTALLATION........................................................................................................................................................1458 MUFFLER.............................................................................................................................................................................1459 REMOVAL AND INSTALLATION........................................................................................................................................................1459 EXHAUST BRAKE.......................................................................................................................................................................1460 REMOVAL AND INSTALLATION........................................................................................................................................................1460 TURBOCHARGER........................................................................................................................................................................1461 REMOVAL AND INSTALLATION........................................................................................................................................................1461 NOZZLE HOLDER.......................................................................................................................................................................1462 REMOVAL AND INSTALLATION........................................................................................................................................................1462 ENGINE FRONT SEAL...................................................................................................................................................................1463 REMOVAL AND INSTALLATION........................................................................................................................................................1463 ENGINE REAR SEAL....................................................................................................................................................................1465 REMOVAL.........................................................................................................................................................................1465 INSTALLATION....................................................................................................................................................................1466 CYLINDER HEAD.......................................................................................................................................................................1469 REMOVAL.........................................................................................................................................................................1469 INSTALLATION....................................................................................................................................................................1473 AIR COMPRESSOR......................................................................................................................................................................1476 REMOVAL.........................................................................................................................................................................1476 INSTALLATION....................................................................................................................................................................1478 ENGINE..............................................................................................................................................................................1480 REMOVAL.........................................................................................................................................................................1480 INSTALLATION....................................................................................................................................................................1483 RADIATOR,POWER TRAIN OIL COOLER,HYDRAULIC COOLER....................................................................................................................................1484 REMOVAL AND INSTALLATION........................................................................................................................................................1484 PTO SET CYLINDER....................................................................................................................................................................1485 REMOVAL AND INSTALLATION........................................................................................................................................................1485 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................1486 ACCELERATOR CONTROL CYLINDER........................................................................................................................................................1487 REMOVAL AND INSTALLATION........................................................................................................................................................1487 DISASSEMBLY.....................................................................................................................................................................1488 ASSEMBLY........................................................................................................................................................................1489 FUEL TANK...........................................................................................................................................................................1490 REMOVAL AND INSTALLATION........................................................................................................................................................1490 DAMPER..............................................................................................................................................................................1491 REMOVAL.........................................................................................................................................................................1491 INSTALLATION....................................................................................................................................................................1493 DAMPER COVER........................................................................................................................................................................1494 DISASSEMBLY.....................................................................................................................................................................1494 ASSEMBLY........................................................................................................................................................................1495 TRANSMISSION........................................................................................................................................................................1497 REMOVAL.........................................................................................................................................................................1497 INSTALLATION....................................................................................................................................................................1500 TRANSMISSION........................................................................................................................................................................1501 DISASSEMBLY.....................................................................................................................................................................1501 ASSEMBLY........................................................................................................................................................................1521 TORQUE CONVERTER....................................................................................................................................................................1547 DISASSEMBLY.....................................................................................................................................................................1547 ASSEMBLY........................................................................................................................................................................1551 TRANSMISSION CONTROL VALVE..........................................................................................................................................................1556 REMOVAL AND INSTALLATION........................................................................................................................................................1556 DISASSEMBLY.....................................................................................................................................................................1557 ASSEMBLY........................................................................................................................................................................1561 HI/LO,2WD/4WD SELECTOR SOLENOID VALVE...............................................................................................................................................1565 REMOVAL AND INSTALLATION........................................................................................................................................................1565 FRONT AXLE..........................................................................................................................................................................1566 REMOVAL.........................................................................................................................................................................1566 INSTALLATION....................................................................................................................................................................1568 REAR AXLE...........................................................................................................................................................................1569 REMOVAL.........................................................................................................................................................................1569 INSTALLATION....................................................................................................................................................................1571 AXLE................................................................................................................................................................................1572 DISASSEMBLY.....................................................................................................................................................................1572 ASSEMBLY........................................................................................................................................................................1578 DIFFERENTIAL........................................................................................................................................................................1587 DISASSEMBLY.....................................................................................................................................................................1587 ASSEMBLY........................................................................................................................................................................1591 PARKING BRAKE SHOE..................................................................................................................................................................1598 REMOVAL.........................................................................................................................................................................1598 INSTALLATION....................................................................................................................................................................1599 WHEEL ASSEMBLY......................................................................................................................................................................1600 REMOVAL AND INSTALLATION........................................................................................................................................................1600 WHEEL BRAKE DISC PLATE..............................................................................................................................................................1601 REMOVAL.........................................................................................................................................................................1601 INSTALLATION....................................................................................................................................................................1603 REAR STEERING LOCK CYLINDER.........................................................................................................................................................1605 REMOVAL AND INSTALLATION........................................................................................................................................................1605 SUSPENSION LOCK CYLINDER............................................................................................................................................................1606 REMOVAL AND INSTALLATION........................................................................................................................................................1606 SUSPENSION LIFT VALVE...............................................................................................................................................................1607 REMOVAL AND INSTALLATION........................................................................................................................................................1607 SWING CIRCLE........................................................................................................................................................................1608 REMOVAL AND INSTALLATION........................................................................................................................................................1608 AIR GOVERNOR........................................................................................................................................................................1609 REMOVAL AND INSTALLATION........................................................................................................................................................1609 AIR REGULATOR VALVE.................................................................................................................................................................1610 REMOVAL AND INSTALLATION........................................................................................................................................................1610 WHEEL BRAKE VALVE...................................................................................................................................................................1611 REMOVAL AND INSTALLATION........................................................................................................................................................1611 WHEEL BRAKE AIR MASTER..............................................................................................................................................................1612 REMOVAL AND INSTALLATION........................................................................................................................................................1612 DISASSEMBLY.....................................................................................................................................................................1613 ASSEMBLY........................................................................................................................................................................1615 PARKING BRAKE SOLENOID VALVE........................................................................................................................................................1618 REMOVAL AND INSTALLATION........................................................................................................................................................1618 AUXILIARY BRAKE SOLENOID VALVE......................................................................................................................................................1618 REMOVAL AND INSTALLATION........................................................................................................................................................1618 EXHAUST BRAKE SOLENOID VALVE........................................................................................................................................................1619 REMOVAL AND INSTALLATION........................................................................................................................................................1619 WHEEL BRAKE CALIPER.................................................................................................................................................................1620 REMOVAL AND INSTALLATION........................................................................................................................................................1620 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................1621 PARKING BRAKE CHAMBER...............................................................................................................................................................1622 REMOVAL AND INSTALLATION........................................................................................................................................................1622 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................1623 HYDRAULIC TANK ASSEMBLY.............................................................................................................................................................1624 REMOVAL AND INSTALLATION........................................................................................................................................................1624 WINCH,BOOM,PPC PUMP.................................................................................................................................................................1625 REMOVAL AND INSTALLATION........................................................................................................................................................1625 TRANSMISSION,STEERING(OUTRIGGER),SWING PUMP.........................................................................................................................................1626 REMOVAL AND INSTALLATION........................................................................................................................................................1626 MAXIMUM FLOW CONTROL VALVE..........................................................................................................................................................1627 REMOVAL AND INSTALLATION........................................................................................................................................................1627 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................1628 CENTER SWIVEL JOINT.................................................................................................................................................................1629 REMOVAL.........................................................................................................................................................................1629 INSTALLATION....................................................................................................................................................................1631 DISASSEMBLY.....................................................................................................................................................................1632 ASSEMBLY........................................................................................................................................................................1634 STEERING PRIORITY VALVE.............................................................................................................................................................1636 REMOVAL AND INSTALLATION........................................................................................................................................................1636 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................1637 STEERING VALVE......................................................................................................................................................................1638 REMOVAL AND INSTALLATION........................................................................................................................................................1638 DISASSEMBLY.....................................................................................................................................................................1639 ASSEMBLY........................................................................................................................................................................1642 EMERGENCY STEERING PUMP.............................................................................................................................................................1646 REMOVAL AND INSTALLATION........................................................................................................................................................1646 EMERGENCY STEERING PUMP,MOTOR.......................................................................................................................................................1647 REMOVAL AND INSTALLATION........................................................................................................................................................1647 STEERING MODE SOLENOID VALVE........................................................................................................................................................1648 REMOVAL AND INSTALLATION........................................................................................................................................................1648 STEERING CYLINDER...................................................................................................................................................................1649 REMOVAL AND INSTALLATION........................................................................................................................................................1649 OUTRIGGER CONTROL VALVE.............................................................................................................................................................1650 REMOVAL AND INSTALLATION........................................................................................................................................................1650 OUTRIGGER JACK CYLINDER CHECK VALVE.................................................................................................................................................1651 REMOVAL AND INSTALLATION........................................................................................................................................................1651 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................1652 OUTRIGGER INDIVIDUAL SOLENOID VALVE.................................................................................................................................................1653 REMOVAL AND INSTALLATION........................................................................................................................................................1653 OUTRIGGER SLIDE CYLINDER(X-SHAPED)..................................................................................................................................................1654 REMOVAL AND INSTALLATION........................................................................................................................................................1654 OUTRIGGER JACK CYLINDER(X-SHAPED)...................................................................................................................................................1655 REMOVAL AND INSTALLATION........................................................................................................................................................1655 DISASSEMBLY.....................................................................................................................................................................1656 ASSEMBLY........................................................................................................................................................................1658 OUTRIGGER SLIDE PILOT CHECK VALVE...................................................................................................................................................1661 REMOVAL AND INSTALLATION........................................................................................................................................................1661 OUTRIGGER SLIDE PILOT CHECK VALVE...................................................................................................................................................1662 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................1662 PPC RELIEF VALVE....................................................................................................................................................................1663 REMOVAL AND INSTALLATION........................................................................................................................................................1663 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................1664 BOOM HOIST,MAIN WINCH,AUXILIARY WINCH PPC VALVE.....................................................................................................................................1665 REMOVAL AND INSTALLATION........................................................................................................................................................1665 JIB POWER TILT,SWING PPC VALVE......................................................................................................................................................1666 REMOVAL.........................................................................................................................................................................1666 INSTALLATION....................................................................................................................................................................1667 BOOM TELESCOPE PPC VALVE............................................................................................................................................................1668 REMOVAL AND INSTALLATION........................................................................................................................................................1668 LEVER CONTROL PPC VALVE.............................................................................................................................................................1669 DISASSEMBLY.....................................................................................................................................................................1669 ASSEMBLY........................................................................................................................................................................1671 PEDAL CONTROL PPC VALVE.............................................................................................................................................................1673 REMOVAL AND INSTALLATION........................................................................................................................................................1673 DISASSEMBLY.....................................................................................................................................................................1674 ASSEMBLY........................................................................................................................................................................1675 WINCH BRAKE MASTER CYLINDER.........................................................................................................................................................1676 REMOVAL AND INSTALLATION........................................................................................................................................................1676 WINCH BRAKE MASTER CYLINDER.........................................................................................................................................................1677 DISASSEMBLY.....................................................................................................................................................................1677 ASSEMBLY........................................................................................................................................................................1678 BOOM,WINCH CONTROL VALVE............................................................................................................................................................1679 REMOVAL.........................................................................................................................................................................1679 INSTALLATION....................................................................................................................................................................1680 DISASSEMBLY.....................................................................................................................................................................1681 ASSEMBLY........................................................................................................................................................................1686 SWING CONTROL VALVE.................................................................................................................................................................1692 REMOVAL AND INSTALLATION........................................................................................................................................................1692 SWING CONTROL VALVE.................................................................................................................................................................1693 DISASSEMBLY.....................................................................................................................................................................1693 ASSEMBLY........................................................................................................................................................................1695 SWING PPC SHUTTLE VALVE.............................................................................................................................................................1697 REMOVAL AND INSTALLATION........................................................................................................................................................1697 SWING BRAKE SOLENOID VALVE..........................................................................................................................................................1698 REMOVAL AND INSTALLATION........................................................................................................................................................1698 SWING MOTOR,SWING MACHINERY.........................................................................................................................................................1699 REMOVAL AND INSTALLATION........................................................................................................................................................1699 SWING FREE SOLENOID VALVE...........................................................................................................................................................1700 REMOVAL AND INSTALLATION........................................................................................................................................................1700 SWING,OUTRIGGER MERGE VALVE.........................................................................................................................................................1701 REMOVAL AND INSTALLATION........................................................................................................................................................1701 SWING,OUTIGGER MERGE SELECTOR SOLENOID VALVE........................................................................................................................................1702 REMOVAL AND INSTALLATION........................................................................................................................................................1702 ACCUMULATOR.........................................................................................................................................................................1703 REMOVAL AND INSTALLATION........................................................................................................................................................1703 ACCUMULATOR.........................................................................................................................................................................1704 DISASSEMBLY.....................................................................................................................................................................1704 ASSEMBLY........................................................................................................................................................................1706 ACCUMULATOR CHARGE VALVE............................................................................................................................................................1708 REMOVAL AND INSTALLATION........................................................................................................................................................1708 DISASSEMBLY.....................................................................................................................................................................1709 ASSEMBLY........................................................................................................................................................................1710 WINCH CLUTCH VALVE..................................................................................................................................................................1711 REMOVAL AND INSTALLATION........................................................................................................................................................1711 DISASSEMBLY.....................................................................................................................................................................1712 ASSEMBLY........................................................................................................................................................................1713 MAIN,AUXILIARY WINCH MOTOR..........................................................................................................................................................1714 REMOVAL AND INSTALLATION........................................................................................................................................................1714 BOOM HOIST CYLINDER.................................................................................................................................................................1715 REMOVAL AND INSTALLATION........................................................................................................................................................1715 BOOM HOIST CYLINDER.................................................................................................................................................................1716 DISASSEMBLY.....................................................................................................................................................................1716 ASSEMBLY........................................................................................................................................................................1719 BOOM TELESCOPE ORDER SELECTOR SOLENOID VALVE........................................................................................................................................1722 REMOVAL AND INSTALLATION........................................................................................................................................................1722 PEDAL CONTROL SELECTOR VALVE........................................................................................................................................................1723 REMOVAL AND INSTALLATION........................................................................................................................................................1723 WINCH BRAKE CALIPER.................................................................................................................................................................1724 REMOVAL AND INSTALLATION........................................................................................................................................................1724 PPC UNLOAD SOLENOID VALVE...........................................................................................................................................................1725 REMOVAL AND INSTALLATION........................................................................................................................................................1725 MAIN UNLOAD SOLENOID VALVE..........................................................................................................................................................1726 REMOVAL AND INSTALLATION........................................................................................................................................................1726 JIB ROTATION CYLINDER...............................................................................................................................................................1727 REMOVAL AND INSTALLATION........................................................................................................................................................1727 JIB POWER TILT CYLINDER.............................................................................................................................................................1728 REMOVAL AND INSTALLATION........................................................................................................................................................1728 DISASSEMBLY.....................................................................................................................................................................1729 ASSEMBLY........................................................................................................................................................................1732 JIB LOCK CYLINDER...................................................................................................................................................................1735 REMOVAL AND INSTALLATION........................................................................................................................................................1735 HYDRAULIC CYLINDER..................................................................................................................................................................1736 DISASSEMBLY.....................................................................................................................................................................1736 ASSEMBLY........................................................................................................................................................................1738 JIB EXTEND/STOW SOLENOID VALVE......................................................................................................................................................1741 REMOVAL AND INSTALLATION........................................................................................................................................................1741 PTO CLUTCH,SUSPENSION LOCK PILOT SELECTOR VALVE.....................................................................................................................................1742 REMOVAL AND INSTALLATION........................................................................................................................................................1742 AIR CONDITIONER COMPRESSOR MOTOR....................................................................................................................................................1743 REMOVAL AND INSTALLATION........................................................................................................................................................1743 AIR CONDITIONER COMPRESSOR MOTOR CHECK VALVE........................................................................................................................................1744 REMOVAL AND INSTALLATION........................................................................................................................................................1744 AIR CONDITIONER MOTOR CHECK VALVE...................................................................................................................................................1745 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................1745 ACCELERATOR CONTROL VALVE...........................................................................................................................................................1746 REMOVAL AND INSTALLATION........................................................................................................................................................1746 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................1747 MAIN WINCH,AUXILIARY WINCH..........................................................................................................................................................1748 REMOVAL.........................................................................................................................................................................1748 INSTALLATION....................................................................................................................................................................1749 MAIN WINCH,AUXILIARY WINCH..........................................................................................................................................................1750 DISASSEMBLY.....................................................................................................................................................................1750 ASSEMBLY........................................................................................................................................................................1755 BOOM................................................................................................................................................................................1761 REMOVAL.........................................................................................................................................................................1761 INSTALLATION....................................................................................................................................................................1764 DISASSEMBLY.....................................................................................................................................................................1765 ASSEMBLY........................................................................................................................................................................1773 BOOM TELESCOPE CYLINDER.............................................................................................................................................................1791 DISASSEMBLY.....................................................................................................................................................................1791 ASSEMBLY........................................................................................................................................................................1794 JIB.................................................................................................................................................................................1797 REMOVAL.........................................................................................................................................................................1797 INSTALLATION....................................................................................................................................................................1799 OUTRIGGER(X-SHAPED).................................................................................................................................................................1802 REMOVAL.........................................................................................................................................................................1802 INSTALLATION....................................................................................................................................................................1803 OPERATOR'S CAB......................................................................................................................................................................1804 REMOVAL.........................................................................................................................................................................1804 INSTALLATION....................................................................................................................................................................1807 REVOLVING FRAME.....................................................................................................................................................................1808 REMOVAL.........................................................................................................................................................................1808 INSTALLATION....................................................................................................................................................................1810 HOOD................................................................................................................................................................................1811 REMOVAL AND INSTALLATION........................................................................................................................................................1811 AIR CONDITIONER COMPRESSOR..........................................................................................................................................................1812 REMOVAL AND INSTALLATION........................................................................................................................................................1812 AIR CONDITIONER CONDENSER...........................................................................................................................................................1813 REMOVAL AND INSTALLATION........................................................................................................................................................1813 UPPER MDT CONTROLLER................................................................................................................................................................1814 REMOVAL AND INSTALLATION........................................................................................................................................................1814 MOMENT LIMITER CONTROLLER...........................................................................................................................................................1815 REMOVAL AND INSTALLATION........................................................................................................................................................1815 LOWER MDT CONTROLLER................................................................................................................................................................1816 REMOVAL AND INSTALLATION........................................................................................................................................................1816 TRANSMISSION CONTROLLER.............................................................................................................................................................1817 REMOVAL AND INSTALLATION........................................................................................................................................................1817 JIB TRANSMISSION MODULE.............................................................................................................................................................1818 REMOVAL AND INSTALLATION........................................................................................................................................................1818 SLIP RING...........................................................................................................................................................................1819 REMOVAL AND INSTALLATION........................................................................................................................................................1819 JIB TILT CORD REEL..................................................................................................................................................................1820 REMOVAL AND INSTALLATION........................................................................................................................................................1820 JIB EXTEND CORD REEL................................................................................................................................................................1821 REMOVAL AND INSTALLATION........................................................................................................................................................1821 OUTRIGGER LENGTH SENSOR.............................................................................................................................................................1822 REMOVAL AND INSTALLATION........................................................................................................................................................1822 BOOM LENGTH SENSOR..................................................................................................................................................................1823 REMOVAL AND INSTALLATION........................................................................................................................................................1823 FRONT HOSE REEL.....................................................................................................................................................................1824 REMOVAL AND INSTALLATION........................................................................................................................................................1824 REAR HOSE REEL......................................................................................................................................................................1825 REMOVAL AND INSTALLATION........................................................................................................................................................1825 40 MAINTENANCE STANDARD.................................................................................................................................................................1826 TORQUE CONVERTER....................................................................................................................................................................1827 PTO CLUTCH..........................................................................................................................................................................1829 TRANSMISSION........................................................................................................................................................................1831 TRANSMISSION CONTROL VALVE..........................................................................................................................................................1838 AXLE................................................................................................................................................................................1841 CHECK VALVE.........................................................................................................................................................................1845 SUSPENSION SYSTEM...................................................................................................................................................................1846 BRAKES..............................................................................................................................................................................1847 PARKING BRAKE.......................................................................................................................................................................1848 BOOM CYLINDER.......................................................................................................................................................................1849 POWER TILT CYLINDER.................................................................................................................................................................1851 LEVER PPC VALVE.....................................................................................................................................................................1852 PEDAL PPC VALVE.....................................................................................................................................................................1853 RELIEF VALVE........................................................................................................................................................................1854 SWING CONTROL VALVE.................................................................................................................................................................1855 BOOM................................................................................................................................................................................1856 JIB.................................................................................................................................................................................1862 HOOK................................................................................................................................................................................1863 WINCH DRUM AND MACHINERY............................................................................................................................................................1864 WINCH BRAKE.........................................................................................................................................................................1865 WINCH CLUTCH........................................................................................................................................................................1866 CHASSIS,H-SHAPED OUTRIGGER..........................................................................................................................................................1867 CHASSIS,X-SHAPED OUTRIGGER..........................................................................................................................................................1869 GUIDE SHEAVE........................................................................................................................................................................1871 REVOLVING FRAME.....................................................................................................................................................................1872 90 OTHERS...............................................................................................................................................................................1873 AIR EQUIPMENT PIPING DRAWING........................................................................................................................................................1874 UNDERCARRIAGE...................................................................................................................................................................1874 UPPER STRUCTURE.................................................................................................................................................................1875 HYDRAULIC CIRCUIT DIAGRAM(STEERING,SWING,SUSPENSION,WORK EQUIPMENT).................................................................................................................1876 UPPER STRUCTURE.................................................................................................................................................................1876 LOWER...........................................................................................................................................................................1877 WORK EQUIPMENT,STEERING HYDRAULIC EQUIPMENT DRAWING.................................................................................................................................1878 UPPER STRUCTURE.................................................................................................................................................................1878 UNDERCARRIAGE(H-SHAPED OUTRIGGER SPECIFICATION).................................................................................................................................1879 UNDERCARRIAGE(X-SHAPED OUTRIGGER SPECIFICATION).................................................................................................................................1880 BOOM............................................................................................................................................................................1881 JIB(MACHINE WITH POWER TILT)....................................................................................................................................................1882 JIB(MACHINE WITH MANUAL TILT JIB)...............................................................................................................................................1883 ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................................................................1884 UPPER STRUCTURE(1/4)............................................................................................................................................................1884 UPPER STRUCTURE(2/4)............................................................................................................................................................1885 UPPER STRUCTURE(3/4)............................................................................................................................................................1886 UPPER STRUCTURE(4/4)............................................................................................................................................................1887 WORK EQUIPMENT(1/2).............................................................................................................................................................1888 WORK EQUIPMENT(2/2).............................................................................................................................................................1889 PANEL(1/2)......................................................................................................................................................................1890 PANEL(2/2)......................................................................................................................................................................1891 UNDERCARRIAGE(1/4)..............................................................................................................................................................1892 UNDERCARRIAGE(2/4)..............................................................................................................................................................1893 UNDERCARRIAGE(3/4)..............................................................................................................................................................1894 UNDERCARRIAGE(4/4)..............................................................................................................................................................1895 ELECTRICAL COMPONENT DIAGRAM........................................................................................................................................................1896 UPPER STRUCTURE.................................................................................................................................................................1896 OVERWIND PREVENTION SYSTEM DRAWING..................................................................................................................................................1899 OVERLOAD SAFETY SYSTEM DRAWING......................................................................................................................................................1900 SYSTEM CONSTRUCTION CHART...........................................................................................................................................................1901 CONNECTOR ALLOCATION DIAGRAM........................................................................................................................................................1902 MOMENT LIMITER SYSTEM ELECTRICAL CIRCUIT DIAGRAM....................................................................................................................................1905 BOOM................................................................................................................................................................................1906 CHASSIS,H-SHAPED OUTRIGGER..........................................................................................................................................................1909 CHASSIS,X-SHAPED OUTRIGGER..........................................................................................................................................................1910
DESCRIPTION:
KOMATSU LW250-5 SHOP MANUAL SEBM008905 – PDF DOWNLOAD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make Judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations perforated in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure. but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to ‘Causes’ are also Included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing. installing, disassembling or assembling each component. as well as precautions to be taken for those operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts
S.S 29/12/24
