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Komatsu WA380 -6 WA380Z-6 WHEEL LOADER Shop Manual – PDF DOWNLOAD
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Komatsu WA380 -6 WA380Z-6 WHEEL LOADER Shop Manual – PDF DOWNLOAD
SERIAL NUMBERS WA380- 65001
WA380Z-66446 and UP
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Description
Komatsu WA380 -6 WA380Z-6 WHEEL LOADER Shop Manual – PDF DOWNLOAD
FILE DETAILS:
Komatsu WA380 -6 WA380Z-6 WHEEL LOADER Shop Manual – PDF DOWNLOAD
Language : English
Pages :2116
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu WA380 -6 WA380Z-6 WHEEL LOADER Shop Manual – PDF DOWNLOAD
SERIAL NUMBERS WA380- 65001
WA380Z-66446 and UP
General precautionsย
Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
5) Only qualified workers must carry out work and operation which require license or qualification.
6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
TABLE OF CONTENTS:
Komatsu WA380 -6 WA380Z-6 WHEEL LOADER Shop Manual – PDF DOWNLOAD
Coverย ย 1
00 Index and forewordย ย 0
Indexย ย 3
Composition of shop manualย ย 4
Table of contentsย ย 6
Foreword and general informationย 19
Safety noticeย 20
How to read the shop manualย 25
Explanation of terms for maintenance standardย 27
Handling of electric equipment and hydraulic componentย 29
Handling of connectors newly used for enginesย 38
How to read electric wire codeย 41
Precautions when carrying out operationย 44
Method of disassembling and connecting push-pull type couplerย 47
Standard tightening torque tableย 50
Conversion tableย 54
01 Specificationย ย 0
Specification and technical dataย 61
Specification dimension drawingย 62
Specificationsย 64
Weight tableย 72
Table of fuel, coolant and lubricantsย 76
10 Structure, function and maintenance standardย ย 0
Engine and cooling systemย 79
Engine mount and transmission mountย 80
Cooling systemย 81
Cooling fan pumpย 83
Break and fan pumpย 90
Cooling fan motorย 91
Power train 105
Power train 107
Power train system diagram 108
Drive shaft 111
Power train piping diagram 112
Torque converter 114
Transmission 122
Flow control valve 156
Valve assembly 158
ECMV 159
Main relief valve and torque converter relief valve 167
Differential 171
Limited slip differential 175
Final drive 182
Steering system 187
Steering piping diagram 188
Steering column 190
Steering pump 192
Steering valve 212
Orbit-roll valve 227
Stop valve 235
Steering relief valve 236
Steering cylinder 237
Emergency steering motor 239
Emergency steering pump 240
Joystick steering lever linkage 241
Steering electric lever 242
Joystick EPC valve 243
Brake system 245
Brake piping diagram 246
Charge valve 248
Brake valve 255
Accumulator (for brake) 260
Brake 262
Parking brake control 267
Parking brake 268
Parking brake solenoid valve 270
Emergency parking brake release valve 272
Undercarriage and frame 275
Axle mount and center hinge pin 276
Tires 281
Hydraulic system, Part 1 283
Hydraulic piping diagram 284
Work equipment control lever linkage 290
Hydraulic tank 293
Power train pump 297
Work equipment pump 298
Work equipment control valve 320
CLSS 348
Each function and operation of each valve 352
Hydraulic system, Part 2 385
PPC valve 386
Stabilizer valve 392
Accumulator (for PPC circuit) 398
Accumulator (for ECSS) 399
Work equipment PPC cut-off solenoid valve 400
Work equipment 403
Work equipment linkage 404
Bucket 408
Bucket positioner and boom kick-out 410
Work equipment cylinder 416
Cab and its attachments 419
Cab 421
Air conditioner 424
Electrical system, Part 1 445
Machine monitor system 446
Machine monitor 454
Electrical system, Part 2 513
Electrical system (Transmission controller system) 514
Transmission controller 558
Electrical system (Work equipment controller system) 562
Work equipment controller 568
Electrical system, Part 3 571
Electric transmission control 572
Kickdown switch and hold switch 576
Multi-function knob 578
Joystick steering knob 579
KOMTRAX terminal system 580
Engine starting circuit 585
Engine stopping circuit 589
Preheating circuit 591
Engine power mode selector circuit 592
Engine output derating function 593
Automatic warm-up function 593
Parking brake circuit 594
Sensor 596
20 Standard value tableย ย 0
Standard service value table 607
Standard service value table for engine 608
Standard service value table for chassis 610
30 Testing and adjustingย ย 0
Testing and adjusting, Part 1 623
Tools for testing, adjusting, and troubleshooting 625
Testing engine speed 632
Testing exhaust gas color 634
Adjusting valve clearance 636
Testing compression pressure 641
Testing blow-by pressure 647
Testing engine oil pressure 648
Testing intake air (boost) pressure 650
Handling fuel system equipment 652
Releasing residual pressure in fuel system 652
Testing fuel pressure 653
Testing fuel delivery, return and leak amount 658
Bleeding air from fuel circuit 666
Testing leakage in fuel system 667
Handling reduced cylinder mode operation 668
Handling no-injection cranking operation 668
Handling controller voltage circuit 669
Testing muffler (main body) and muffler stack for looseness or damage 669
Testing muffler for functions 670
Testing cylinder head and manifold parts for tightness 670
Testing engine piping for damage and tightness 671
Testing and adjusting air conditioner compressor belt tension 672
Replacing alternator belt 673
Adjusting transmission speed sensor 675
Adjusting length of directional lever 676
Adjusting length of gearshift lever 676
Testing directional lever 677
Testing and adjusting power train oil pressure 678
Procedure for flushing torque converter and transmission hydraulic circuit 707
Method of moving machine when transmission valve is broken 708
Testing axel end for oil leakage 712
Testing drive shaft for looseness, backlash and damage 712
Testing and adjusting steering stop valve 713
Testing and adjusting steering wheel 715
Testing and adjusting steering oil pressure 717
Bleeding air from steering circuit 720
Testing and adjusting, Part 2 723
Testing hydraulic drive fan 725
Bleeding air from hydraulic drive fan circuit 729
Testing brake pedal 732
Testing and adjusting brake pedal linkage 733
Testing brake performance 734
Testing and adjusting accumulator charge pressure 735
Testing wheel brake oil pressure 737
Testing wheel brake oil pressure drop 738
Testing wear of wheel brake disc1 740
Bleeding air from wheel brake circuit 741
Releasing residual pressure in brake accumulator circuit 742
Testing parking brake performance 743
Testing parking brake oil pressure 744
Testing wear of parking brake disc 746
Method of releasing parking brake manually 747
Testing and adjusting work equipment control lever 748
Testing and adjusting work equipment PPC oil pressure 749
Testing and adjusting work equipment oil pressure 755
Bleeding air from work equipment circuit 759
Releasing residual pressure in work equipment circuit 760
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator 762
Testing and adjusting bucket positioner 768
Testing and adjusting boom kick-out 770
Checking proximity switch operation pilot lamp 771
Procedure for testing diodes 772
Preparation work for troubleshooting for electric system 773
How to start operation of KOMTRAX terminal 782
Lamp display of KOMTRAX terminal 787
Testing and adjusting, Part 3 791
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor 793
Special functions of machine monitor (EMMS) 795
Pm-clinic inspection table 864
40 Troubleshootingย ย 0
Failure code table and fuse locations 871
Failure code table 872
Fuse locations 889
General information on troubleshooting 895
Points to remember when troubleshooting 896
Sequence of events in troubleshooting 897
Testing before troubleshooting 899
Classification and procedures of troubleshooting 900
Information contained in troubleshooting table 903
Connection table for connector pin numbers 905
T- branch box and T- branch adapter table 941
Troubleshooting by failure code (Display of code), Part 1 945
Failure code [1500L0] (TORQFLOW transmission: Double meshing) 947
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) 950
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) 952
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) 954
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) 956
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) 958
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) 960
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) 962
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON) 964
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) 966
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON) 968
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) 970
Failure code [2F00MA] (Parking brake: Malfunction) 972
Failure code [2G43ZG] (Accumulator: Low oil pressure) 975
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) 979
Troubleshooting by failure code (Display of code), Part 2 983
Failure code [AA1ANX] (Air cleaner: Clogging) 986
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) 989
Failure code [AB00MA] (Alternator: Malfunction) 993
Failure code [B@BAZG] (Rotation derating by low engine oil pressure) 997
Failure code [B@BAZK] (Engine oil: Low level) 998
Failure code [B@BCNS] (Coolant: Overheating) 999
Failure code [B@BCZK] (Coolant: Low level)1001
Failure code [B@BEBF] (Water in fuel error)1004
Failure code [B@C7NS] (Brake oil: Overheating)1006
Failure code [b@CENS] (Torque converter oil: Overheating)1008
Failure code [B@CENS] (Torque converter oil: Overheating)1011
Failure code [B@HANS] (Hydraulic oil: Overheating)1014
Failure code [CA111] (Abnormality in engine controller)1016
Failure code [CA115] (Engine Ne or Bkup speed sensor error)1017
Failure code [CA122] (Charge pressure sensor high error)1018
Failure code [CA123] (Charge pressure sensor low error)1020
Failure code [CA131] (Throttle sensor high error)1022
Failure code [CA132] (Throttle sensor low error)1024
Failure code [CA144] (Coolant sensor high error)1026
Failure code [CA145] (Coolant sensor low error)1028
Failure code [CA153] (Charge temperature sensor high error)1030
Failure code [CA154] (Charge temperature sensor low error)1032
Failure code [CA155] (Derating of speed by abnormally high charge temperature)1034
Failure code [CA187] (Sensor power supply 2 low error)1036
Failure code [CA221] (Atmospheric pressure sensor high error)1038
Failure code [CA222] (Atmospheric sensor low error)1040
Failure code [CA227] (Sensor power supply 2 high error)1042
Failure code [CA234] (Engine overspeed)1043
Failure code [CA238] (Ne speed sensor power supply error)1044
Troubleshooting by failure code (Display of code), Part 31047
Failure code [CA271] (IMV/PCV1 Short circuit)1049
Failure code [CA272] (IMV/PCV1 Disconnection)1050
Failure code [CA322] (Injector #1 open/short error)1052
Failure code [CA323] (Injector #5 open/short error)1054
Failure code [CA324] (Injector #3 open/short error)1056
Failure code [CA325] (Injector #6 open/short error)1058
Failure code [CA331] (Injector #2 open/short error)1060
Failure code [CA332] (Injector #4 open/short error)1062
Failure code [CA342] (Calibration code inconsistency)1064
Failure code [CA351] (Injectors drive circuit error)1066
Failure code [CA352] (Sensor power supply 1 low error)1069
Failure code [CA386] (Sensor power supply 1 high error)1071
Failure code [CA428] (Abnormally high level in water sensor)1072
Failure code [CA429] (Abnormally low level in water sensor)1073
Failure code [CA431] (Idle validation switch error)1074
Failure code [CA432] (Idle validation action error)1077
Failure code [CA435] (Engine oil pressure switch error)1079
Failure code [CA441] (Battery voltage low error)1080
Failure code [CA442] (Battery voltage high error)1084
Failure code [CA449] Common rail pressure high error 21087
Failure code [CA451] (Common rail pressure sensor high error)1089
Failure code [CA452] (Common rail pressure sensor low error)1091
Failure code [CA488] (Derating of torque by abnormally high charge temperature)1093
Failure code [CA553] (Common rail pressure high error 1)1094
Failure code [CA559] (Supply pump pressure very low error)1095
Failure code [CA689] (Engine Ne speed sensor error)1097
Failure code [CA731] (Engine Bkup speed sensor phase error)1099
Failure code [CA757] (All continuous data lost error)1100
Failure code [CA778] (Engine Bkup speed sensor error)1104
Failure code [CA1633] (KOMNET datalink timeout error)1107
Failure code [CA2185] (Throttle sensor power supply voltage high error)1110
Failure code [CA2186] (Throttle sensor power supply voltage low error)1111
Troubleshooting by failure code (Display of code), Part 41113
Failure code [CA2249] (Supply pump pressure very low error 2)1115
Failure code [CA2311] (Abnormality in IMV solenoid)1116
Failure code [CA2555] (Intake heater relay disconnection error)1118
Failure code [CA2556] (Intake heater relay short circuit error)1121
Failure code [D150KA] (Emergency steering relay: Disconnection)1124
Failure code [D150KB] (Emergency steering relay: Short circuit)1127
Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)1130
Failure code [D160KA] (Backup lamp relay: Disconnection)1133
Failure code [D160KB] (Backup lamp relay: Short circuit)1136
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)1139
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)1141
Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)1143
Failure code [D192KA] (ECSS solenoid: Disconnection)1145
Failure code [D192KB] (ECSS solenoid: Short circuit)1146
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)1147
Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection)1148
Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit)1150
Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line)1152
Failure code [D5ZHKA] (Terminal C signal: Disconnection)1155
Failure code [D5ZHKB] (Terminal C signal: Short circuit)1161
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)1166
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)1173
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)1178
Failure code [DAF3KK] (Machine monitor: Low source voltage (input)1180
Failure code [DAF5KP] (Machine monitor: Low output voltage)1184
Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system)1188
Troubleshooting by failure code (Display of code), Part 51193
Failure code [DAQ0KK] (Transmission controller: Low source voltage)1196
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)1200
Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)1201
Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)1204
Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)1205
Failure code [DAQRMA] (Transmission controller option setting: Malfunction)1211
Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)1212
Failure code [DB90KK] Work equipment controller: Low source voltage (input)1216
Failure code [DB90KT] Work equipment controller: Abnormality in controller1218
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)1219
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range1221
Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)1224
Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)1225
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)1227
Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation)1228
Failure code [DD15LD] โ switch (Panel switch 1): Switch is kept pressed for long time1232
Failure code [DD16LD] <> switch (Panel switch 2) : Switch is kept pressed for long time1235
Failure code [DD17LD] < switch (Panel switch 3) : Switch is kept pressed for long time1238
Failure code [DD18LD] > switch (Panel switch 4) : Switch is kept pressed for long time1241
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise) : Switch is kept pressed for long time1244
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower) : Switch is kept pressed for long time1246
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time1248
Failure code [DD1FLD] Load meter mode selector switch (A/B) : Switch is kept pressed for long time1250
Failure code [DD1GLD] Load meter mode selector switch (+/โ) : Switch is kept pressed for long time1252
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)1254
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)1256
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)1258
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)1260
Troubleshooting by failure code (Display of code), Part 61265
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)1268
Failure code [DDK3KA] (Right FNR switch: Disconnection)1271
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)1274
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)1277
Failure code [DDK6KA] (FNR lever switch: Disconnection)1279
Failure code [DDK6KB] (FNR lever switch: Short circuit)1286
Failure code [DDS5KA] (Steering pressure switch: Disconnected)1290
Failure code [DDS5KB] (Steering pressure switch: Grounded)1292
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)1294
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)1297
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)1300
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)1303
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)1306
Failure code [DF10KA] (Transmission shift lever switch: Disconnected)1308
Failure code [DF10KB] (Transmission shift lever switch: Short circuit)1312
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)1315
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)1318
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)1321
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)1323
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)1325
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)1327
Failure code [DH21KA] (Loader pump pressure sensor: Disconnection)1330
Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short)1332
Troubleshooting by failure code (Display of code), Part 71335
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)1338
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)1340
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)1342
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)1346
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)1348
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)1350
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)1353
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)1356
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)1359
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)1362
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)1365
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)1368
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)1371
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)1374
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)1377
Troubleshooting by failure code (Display of code), Part 81381
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)1383
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)1386
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)1388
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)1392
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)1394
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)1398
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)1400
Failure code [DKA0L0] (Lift arm angle sensor: Dislocation of sensor)1402
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)1404
Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)1406
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)1408
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)1412
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)1414
Failure code [DV00KB] (Alarm buzzer: Short circuit)1416
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)1418
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)1420
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)1422
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)1424
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)1425
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)1426
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)1428
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)1429
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)1430
Troubleshooting by failure code (Display of code), Part 91433
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)1435
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)1436
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)1438
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)1440
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)1442
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)1444
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)1446
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)1448
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)1450
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)1452
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)1454
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)1456
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)1458
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)1460
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)1462
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)1464
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)1466
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)1468
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)1470
Failure code [DX16KA] (Fan motor EPC solenoid: Disconnection)1471
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)1472
Failure code [DX16KB] (Fan motor EPC solenoid: Short circuit)1473
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)1474
Failure code [DX16KY] (Fan motor EPC solenoid: Short circuit with power supply line)1475
Failure code [DXA1KA] (Loader pump EPC solenoid: Disconnection)1476
Failure code [DXA1KB] (Loader pump EPC solenoid: Short circuit)1478
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)1480
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)1482
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)1484
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)1486
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)1488
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)1490
Troubleshooting by failure code (Display of code), Part 101493
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)1496
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)1498
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)1500
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)1502
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)1504
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)1506
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)1508
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)1510
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)1512
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)1514
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)1516
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)1518
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)1520
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)1522
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)1524
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)1526
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)1528
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)1530
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)1532
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)1534
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)1536
Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine)1538
Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode)1543
Troubleshooting of electrical system (E-mode)1551
Installing positions of fuses1553
Information in troubleshooting table1558
E-1 Engine does not start1559
E-2 Wiper does not operate1572
E-3 Windshield washer does not operate1577
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off1581
E-5 Working lamp does not light up or go off1597
E-6 Turn signal lamp and hazard lamp do not light up or go off1607
E-7 Brake lamp does not light or it keeps lighting up1619
E-8 Backup lamp does not light or it keeps lighting up1623
E-9 Backup buzzer does not sound or it keeps sounding1627
E-10 Horn does not sound or it keeps sounding1630
E-11 Alarm buzzer does not sound or it keeps sounding1634
E-12 Air conditioner does not operate or stop1636
E-13 The KOMTRAX system does not work properly1640
E-14 When kick-down switch is turned ON, kick-down operation does not start1643
E-15 When hold switch is pressed, holding operation does not start1646
E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied1649
E-17 Transmission cut-off mode cannot be set or reset1652
E-18 Transmission cut-off set cannot be reset1655
E-19 FNR switch mode cannot be set or reset1658
E-20 Fan reverse function cannot be used or reset1660
E-21 Discharge from loader pump does not rise from minimum level1662
E-22 ECSS function cannot be used or reset1664
E-23 When parking brake is turned ON, parking brake indicator lamp does not light up1666
E-24 When emergency brake operates, brake oil pressure caution lamp does not operate1670
E-25 Air cleaner clogging indicator lamp does not light up1674
E-26 Radiator coolant level caution lamp does not light up1677
E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light1679
ๅ็งฐๆช่จญๅฎ1681
E-29 Steering oil pressure caution lamp does not light up1683
E-30 Abnormality in โ switch (panel switch 1) input1686
E-31 Abnormality in <> switch (panel switch 2) input1689
E-32 Abnormality in < switch (panel switch 3) input1692
E-33 Abnormality in > switch (panel switch 4) input1695
Troubleshooting of hydraulic and mechanical system (H-mode)1699
Method of using troubleshooting chart1701
Table of failure modes and causes1704
H-1 The machine does not start1712
H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch]1714
H-3 Torque converter lockup is not switched on [Machine with lockup clutch]1715
H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted1716
H-5 Shocks are large at the times of starting and shifting gear1718
H-6 Time lag is large at the times of starting and shifting gear1720
H-7 The torque converter oil temperature is high1722
H-8 Steering does not turn1723
H-9 Steering does not turn [Machine with joystick steering]1724
H-10 Steering response is low1725
H-11 Turning, response of steering is poor [machine with joystick steering]1726
H-12 Steering is heavy1727
H-13 When machine turns, it shakes or makes large shocks1728
H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering]1729
H-15 The wheel brake does not work or does not work well1730
H-16 The wheel brake is not released or it drags1731
H-17 The parking brake does not work or does not work well1732
H-18 The parking brake is not released or it drags (including emergency release system)1733
H-19 Lift arm does not rise1734
H-20 Lift arm speed is low or rising force of lift arm is insufficient1735
H-21 When rising, the lift arm comes to move slowly at specific height1736
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)1736
H-23 Hydraulic drifts of the lift arm is large1736
H-24 The lift arm wobbles during operation1736
H-25 Bucket does not tilt back1737
H-26 Bucket speed is low or tilting back force is insufficient1738
H-27 The bucket comes to operate slowly in the midst of tilting-back1739
H-28 The bucket cylinder cannot hold down the bucket1739
H-29 Hydraulic drifts of the bucket is large1739
H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to โHOLDโ)1739
H-31 Lift arm and bucket control levers do not move smoothly and are heavy1740
H-32 During operation of the machine, engine speed lowers remarkably or engine stalls1741
H-33 Large shock is made when work equipment starts and stops1741
H-34 When work equipment circuit is relieved singly, other work equipment moves1741
H-35 ECSS does not operate, and pitching, bouncing occur1742
H-36 Fan revolution is abnormal (Fan sound/ vibration is abnormally large or engine overheats)1743
Troubleshooting of engine (S-mode)1745
Method of using troubleshooting charts1747
S-1 Engine does not start easily1750
S-2 Engine does not start1751
S-3 Engine does not pick up smoothly1754
S-4 Engine stops during operations1755
S-5 Engine does not rotate smoothly1756
S-6 Engine lacks output (or lacks power)1757
S-7 Exhaust smoke is black (Incomplete combustion)1758
S-8 Oil consumption is excessive (or exhaust smoke is blue)1759
S-9 Engine oil becomes contaminated quickly1760
S-10 Fuel consumption is excessive1761
S-11 Coolant contains oil (blows back or reduces)1762
S-12 Oil pressure drops1763
S-13 Oil level rises (Water, fuel in oil)1764
S-14 Coolant temperature rises too high (Overheating)1765
S-15 Abnormal noise is made1766
S-16 Vibration is excessive1767
50 Disassembly and assemblyย ย 0
General information on disassembly and assembly1769
How to read this manual1770
Special tools list1775
Sketches of special tools1778
Engine and cooling system1785
Removal and installation of fuel supply pump assembly1786
Removal and installation of fue linjector assembly1790
Removal and installation of cylinder head assembly1804
Removal and installation of engine hood assembly1826
Removal and installation of radiator assembly1831
Removal and installation of air aftercooler1836
Removal and installation of hydraulic oil cooler assembly1838
Removal and installation of engine assembly1840
Removal and installation of engine front oil seal assembly1845
Removal and installation of engine rear oil seal assembly1848
Removal and installation of cooling fan and fan motor assembly1851
Removal and installation of fuel tank assembly1857
Power train1861
Removal and installation of torque converter and transmission assembly1862
Disassembly and assembly of torque converter assembly (Standard specification)1868
Disassembly and assembly of torque converter assembly (Lockup specification)1872
Disassembly and assembly of transmission assembly1878
Disassembly and assembly of transmission clutch pack assembly1895
Disassembly and assembly of parking brake assembly1914
Removal and installation of front axle assembly1923
Removal and installation of rear axle assembly1925
Disassembly and assembly of axle housing1928
Disassembly and assembly of differential assembly1937
Steering system1957
Removal and installation of steering valve assembly1958
Brake system1963
Removal and installation of parking brake discs and plates1964
Undercarriage and frame1969
Removal and installation of center hinge pin1970
Removal and installation of counterweight1978
Hydraulic system1983
Removal and installation of work equipment control valve assembly1984
Removal and installation of power train pump and work equipment pump assembly1990
Removal and installation of steering pump and cooling fan pump assembly1991
Removal and installation of hydraulic tank assembly1993
Work equipment1997
Removal and installation of work equipment assembly1998
Disassembly and assembly of hydraulic cylinder assembly2002
Cab and its attachments2011
Removal and installation of operator’s cab and floor frame assembly2012
Removal and installation of operator’s cab glass (stuck glass)2019
Disassembly and assembly of operator’s seat assembly (Standard specification)2027
Disassembly and assembly of operator’s seat assembly (Manufactured by GRAMMER)2036
Removal and installation of air conditioner unit assembly2069
Electrical system2073
Removal and installation of engine controller assembly2074
90 Diagrams and drawingsย ย 0
Hydraulic diagrams and drawings2077
Power train hydraulic circuit diagram2078
Automatic greasing circuit diagram2080
Hydraulic circuit diagram2083
Electrical diagrams and drawings2087
Electrical circuit diagram2089
Work equipment controller system electrical circuit diagram2112
Connector list and stereogram2113
IMAGES PREVIEW OF THE MANUAL:
S.M 13/12/24
