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KOMATSU WA380-6 WHEEL LOADER SERVICE REPAIR MANUAL (SN:65001 & UP) – PDF Download
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- KOMATSU WA380-6 WHEEL LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBER:65001 & UP
- PUBLICATION NUMBER:SEN00769-03
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Description
KOMATSU WA380-6 WHEEL LOADER SERVICE REPAIR MANUAL (SN:65001 & UP)
KOMATSU WA380-6 WHEEL LOADER SERVICE REPAIR MANUAL (SN:65001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA380-6 WHEEL LOADER SERVICE REPAIR MANUAL (SN:65001 & UP)
This shop manual contains the necessary technical information for services performed in a workshop.For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing arts.
TABLE OF CONTENTS:
KOMATSU WA380-6 WHEEL LOADER SERVICE REPAIR MANUAL (SN:65001 & UP)
COVER.................................................................................................................................................... 1 00 Index and foreword.................................................................................................................................... 3 Index................................................................................................................................................ 3 Composition of shop manual....................................................................................................................... 4 Table of contents................................................................................................................................ 6 Foreword and general information..................................................................................................................... 19 Safety notice.................................................................................................................................... 20 How to read the shop manual...................................................................................................................... 25 Explanation of terms for maintenance standard.................................................................................................... 27 Handling electric equipment and hydraulic component.............................................................................................. 29 How to read electric wire code................................................................................................................... 41 Precautions when carrying out operation.......................................................................................................... 44 Method of disassembling and connecting push-pull type coupler.................................................................................... 47 Standard tightening torque table................................................................................................................. 50 Conversion table................................................................................................................................. 54 01 Specification......................................................................................................................................... 61 Specification and technical data..................................................................................................................... 61 Specification and technical data................................................................................................................. 63 Specification dimension drawing.............................................................................................................. 63 Specifications............................................................................................................................... 64 Weight table................................................................................................................................. 68 Table of fuel, coolant and lubricants........................................................................................................ 70 10 Structure, function and maintenance standard.......................................................................................................... 73 Engine and cooling system............................................................................................................................ 73 Engine and cooling system........................................................................................................................ 74 Engine mount and transmission mount.......................................................................................................... 74 Cooling system............................................................................................................................... 75 Cooling fan pump............................................................................................................................. 76 Cooling fan motor............................................................................................................................ 84 Power train.......................................................................................................................................... 91 Power train...................................................................................................................................... 93 Power train.................................................................................................................................. 93 Power train system diagram................................................................................................................... 94 Drive shaft.................................................................................................................................. 96 Power train piping diagram................................................................................................................... 97 Torque converter............................................................................................................................. 98 Transmission................................................................................................................................. 106 Flow control valve........................................................................................................................... 123 Valve assembly............................................................................................................................... 124 ECMV......................................................................................................................................... 125 Main relief valve and torque converter relief valve.......................................................................................... 132 Axle......................................................................................................................................... 134 Front axle................................................................................................................................... 134 Rear axle.................................................................................................................................... 135 Differential................................................................................................................................. 136 Front differential........................................................................................................................... 136 Rear differential............................................................................................................................ 137 Limited slip differential.................................................................................................................... 141 Final drive.................................................................................................................................. 148 Steering system...................................................................................................................................... 153 Steering system.................................................................................................................................. 154 Steering piping diagram...................................................................................................................... 154 Steering column.............................................................................................................................. 155 Steering pump................................................................................................................................ 156 Steering valve............................................................................................................................... 167 Orbit-roll valve............................................................................................................................. 182 Stop valve................................................................................................................................... 186 Steering relief valve........................................................................................................................ 187 Steering cylinder............................................................................................................................ 188 Emergency steering motor..................................................................................................................... 190 Emergency steering pump...................................................................................................................... 191 Brake system......................................................................................................................................... 193 Brake system..................................................................................................................................... 194 Brake piping diagram......................................................................................................................... 194 Charge valve................................................................................................................................. 195 Brake valve.................................................................................................................................. 202 Accumulator (for brake)...................................................................................................................... 207 Brake........................................................................................................................................ 208 Parking brake control........................................................................................................................ 213 Parking brake................................................................................................................................ 214 Parking brake solenoid valve................................................................................................................. 216 Emergency parking brake release valve........................................................................................................ 218 Undercarriage and frame.............................................................................................................................. 221 Undercarriage and frame.......................................................................................................................... 222 Axle mount and center hinge pin.............................................................................................................. 222 Tires........................................................................................................................................ 226 Hydraulic system, Part 1............................................................................................................................. 229 Hydraulic system, Part 1......................................................................................................................... 230 Hydraulic piping diagram..................................................................................................................... 230 Work equipment control lever linkage......................................................................................................... 233 Hydraulic tank............................................................................................................................... 234 Breather..................................................................................................................................... 235 Power train pump............................................................................................................................. 236 Work equipment pump.......................................................................................................................... 237 Work equipment control valve................................................................................................................. 248 CLSS......................................................................................................................................... 262 Outline of CLSS.............................................................................................................................. 262 Basic principle.............................................................................................................................. 263 Each function and operation of each valve.................................................................................................... 266 Hydraulic circuit diagram and names of valves................................................................................................ 266 Area ratio of pressure compensation valve.................................................................................................... 276 Lift arm regeneration circuit................................................................................................................ 278 Variable lift check valve.................................................................................................................... 280 ECSS control valve........................................................................................................................... 281 Restriction on lift arm raise stroke......................................................................................................... 282 Accumulator charge valve..................................................................................................................... 284 Hydraulic system, Part 2............................................................................................................................. 289 Hydraulic system, Part 2......................................................................................................................... 290 PPC valve.................................................................................................................................... 290 Stabilizer valve............................................................................................................................. 296 Accumulator (for PPC circuit)................................................................................................................ 301 Accumulator (for ECSS)....................................................................................................................... 302 Work equipment....................................................................................................................................... 305 Work equipment................................................................................................................................... 306 Work equipment linkage....................................................................................................................... 306 Bucket....................................................................................................................................... 308 Bucket positioner and boom kick-out.......................................................................................................... 309 Work equipment cylinder...................................................................................................................... 315 Cab and its attachments.............................................................................................................................. 317 Cab and its attachments.......................................................................................................................... 319 Cab.......................................................................................................................................... 319 Air conditioner.............................................................................................................................. 320 Air conditioner piping diagram............................................................................................................... 320 Air conditioner unit......................................................................................................................... 323 Blower and intake unit....................................................................................................................... 325 Compressor................................................................................................................................... 326 Condenser.................................................................................................................................... 327 Receiver..................................................................................................................................... 328 Air conditioner panel........................................................................................................................ 330 Electrical system, Part 1............................................................................................................................ 333 Electrical system, Part 1........................................................................................................................ 334 Machine monitor system....................................................................................................................... 334 System circuit diagram....................................................................................................................... 336 Machine monitor.............................................................................................................................. 339 List of items displayed on monitor........................................................................................................... 340 Machine monitor operation switch............................................................................................................. 344 Setting of machine monitor................................................................................................................... 345 Character display............................................................................................................................ 346 Operator mode functions...................................................................................................................... 347 Service mode functions....................................................................................................................... 350 Input and output signals..................................................................................................................... 355 Electrical system, Part 2............................................................................................................................ 361 Electrical system, Part 2........................................................................................................................ 362 Electrical system (Transmission controller system)........................................................................................... 362 Transmission controller...................................................................................................................... 394 Electrical system, Part 3............................................................................................................................ 397 Electrical system, Part 3........................................................................................................................ 397 Electric transmission control................................................................................................................ 398 Kickdown switch and hold switch.............................................................................................................. 402 KOMTRAX terminal system...................................................................................................................... 404 Engine starting circuit...................................................................................................................... 406 Engine stopping circuit...................................................................................................................... 408 Preheating circuit........................................................................................................................... 409 Engine power mode selector circuit........................................................................................................... 410 Engine output derating function.............................................................................................................. 411 Parking brake circuit........................................................................................................................ 412 Automatic warm-up function................................................................................................................... 411 Sensor....................................................................................................................................... 414 20 Standard value table.................................................................................................................................. 423 Standard service value table......................................................................................................................... 423 Standard service value table..................................................................................................................... 424 Standard service value table for engine...................................................................................................... 424 Standard service value table for chassis..................................................................................................... 425 30 Testing and adjusting................................................................................................................................. 433 Testing and adjusting, Part 1........................................................................................................................ 433 Testing and adjusting, Part 1.................................................................................................................... 435 Tools for testing, adjusting, and troubleshooting............................................................................................ 435 Measuring engine speed....................................................................................................................... 438 Measuring exhaust gas color.................................................................................................................. 440 Adjusting valve clearance.................................................................................................................... 442 Measuring compression pressure............................................................................................................... 444 Measuring blow-by pressure................................................................................................................... 447 Measuring engine oil pressure................................................................................................................ 448 Measuring intake air (boost) pressure........................................................................................................ 449 Handling fuel system equipment............................................................................................................... 450 Releasing residual pressure in fuel system................................................................................................... 450 Measuring fuel pressure...................................................................................................................... 451 Measuring fuel return rate and leakage....................................................................................................... 453 Bleeding air from fuel circuit............................................................................................................... 456 Testing leakage in fuel system............................................................................................................... 458 Handling reduced cylinder mode operation..................................................................................................... 459 Handling no-injection cranking operation..................................................................................................... 459 Handling controller voltage circuit.......................................................................................................... 460 Testing and adjusting air conditioner compressor belt tension................................................................................ 461 Adjusting transmission speed sensor.......................................................................................................... 462 Measuring directional lever.................................................................................................................. 463 Measuring and adjusting power train oil pressure............................................................................................. 464 Procedure for flushing torque converter and transmission hydraulic circuit................................................................... 479 Method of moving machine when transmission valve is broken................................................................................... 480 Testing and adjusting steering stop valve.................................................................................................... 482 Testing and adjusting steering wheel......................................................................................................... 484 Testing steering oil pressure................................................................................................................ 486 Bleeding air from steering circuit........................................................................................................... 489 Testing and adjusting, Part 2........................................................................................................................ 491 Testing and adjusting, Part 2.................................................................................................................... 493 Testing hydraulic drive fan.................................................................................................................. 493 Bleeding air from hydraulic drive fan circuit................................................................................................ 495 Measuring brake pedal........................................................................................................................ 497 Measuring brake performance.................................................................................................................. 498 Testing and adjusting accumulator charge pressure............................................................................................ 499 Testing wheel brake oil pressure............................................................................................................. 500 Measuring wear of wheel brake disc........................................................................................................... 502 Bleeding air from wheel brakecircuit......................................................................................................... 503 Releasing residual pressure in brake accumulator circuit..................................................................................... 504 Testing parking brake performance............................................................................................................ 505 Measuring parking brake oil pressure......................................................................................................... 506 Testing wear of parking brake disc........................................................................................................... 508 Method of releasing parking brake manually................................................................................................... 509 Measuring and adjusting work equipment control lever......................................................................................... 510 Measuring and adjusting work equipment PPC oil pressure...................................................................................... 511 Measuring and adjusting work equipment oil pressure.......................................................................................... 514 Bleeding air from work equipment circuit..................................................................................................... 518 Releasing residual pressure in work equipment circuit........................................................................................ 519 Testing and adjusting bucket positioner...................................................................................................... 520 Testing and adjusting boom kickout........................................................................................................... 522 Checking proximity switch operation pilot lamp............................................................................................... 523 Procedure for testing diodes................................................................................................................. 524 Preparation work for troubleshooting for electric system..................................................................................... 525 How to start operation of KOMTRAX terminal................................................................................................... 530 Lamp display of KOMTRAX terminal............................................................................................................. 535 Adjusting machine monitor.................................................................................................................... 538 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor....................................................... 539 Testing and adjusting, Part 3........................................................................................................................ 543 Testing and adjusting, Part 3.................................................................................................................... 544 Special functions of machine monitor (EMMS).................................................................................................. 544 Pm-click inspection table.................................................................................................................... 603 40 Troubleshooting....................................................................................................................................... 607 General information on troubleshooting............................................................................................................... 607 General information on troubleshooting........................................................................................................... 608 Points to remember when troubleshooting...................................................................................................... 608 Sequence of events in troubleshooting........................................................................................................ 609 Testing before troubleshooting............................................................................................................... 610 Classification and procedures of troubleshooting............................................................................................. 611 Connection table for connector pin numbers................................................................................................... 614 T-branch box and T-branch adapter table...................................................................................................... 637 Troubleshooting by failure code (Display of code), Part 1............................................................................................ 641 Troubleshooting by failure code (Display of code), Part 1........................................................................................ 643 Failure codes list........................................................................................................................... 643 Before carrying out troubleshooting for electrical system.................................................................................... 650 Information contained troubleshooting table.................................................................................................. 653 Failure code [1500L0] (TORQFLOW transmission: Double meshing)................................................................................ 655 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)........................................................ 656 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)........................................................ 658 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)........................................................ 660 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)........................................................ 662 Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)...................................................... 664 Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)...................................................... 666 Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)...................................................... 668 Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)...................................................... 670 Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)...................................................... 672 Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)...................................................... 674 Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)...................................................... 676 Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)...................................................... 678 Failure code [2F00MA] (Parking brake: Malfunction)........................................................................................... 680 Troubleshooting by failure code (Display of code), Part 2............................................................................................ 683 Troubleshooting by failure code (Display of code), Part 2........................................................................................ 686 Failure code [2G43ZG] (Accumulator: Low oil pressure)........................................................................................ 686 Failure code [AA1ANX] (Air cleaner: Clogging)................................................................................................ 688 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine).......................................................... 690 Failure code [AB00MA] (Alternator: Malfunction).............................................................................................. 692 Failure code [B@BAZG] (Rotation derating by low engine oil pressure)......................................................................... 694 Failure code [B@BAZK] (Engine oil: Low level)................................................................................................ 695 Failure code [B@BCNS] (Coolant: Overheating)................................................................................................. 696 Failure code [B@BCZK] (Coolant: Low level)................................................................................................... 698 Failure code [B@C7NS] (Brake oil: Overheating)............................................................................................... 700 Failure code [b@CENS] (Torque converter oil: Overheating).................................................................................... 702 Failure code [B@CENS] (Torque converter oil: Overheating).................................................................................... 704 Failure code [B@HANS] (Hydraulic oil: Overheating)........................................................................................... 706 Failure code [CA111] (Abnormality in engine controller)...................................................................................... 708 Failure code [CA115] (Engine Ne or Bkup speed sensor error).................................................................................. 709 Failure code [CA122] (Charge pressure sensor high error)..................................................................................... 710 Failure code [CA123] (Charge pressure sensor low error)...................................................................................... 712 Failure code [CA131] (Throttle sensor high error)............................................................................................ 714 Failure code [CA132] (Throttle sensor low error)............................................................................................. 716 Failure code [CA144] (Coolant sensor high error)............................................................................................. 718 Failure code [CA145] (Coolant sensor low error).............................................................................................. 720 Failure code [CA153] (Charge temperature sensor high error).................................................................................. 722 Failure code [CA154] (Charge temperature sensor low error)................................................................................... 724 Failure code [CA155] (Derating of speed by abnormally high charge temperature)............................................................... 726 Failure code [CA187] (Sensor power supply 2 low error)....................................................................................... 728 Failure code [CA221] (Atmospheric pressure sensor high error)................................................................................ 730 Failure code [CA222] (Atmospheric sensor low error).......................................................................................... 732 Failure code [CA227] (Sensor power supply 2 high error)...................................................................................... 734 Troubleshooting by failure code (Display of code), Part 3............................................................................................ 737 Troubleshooting by failure code (Display of code), Part 3........................................................................................ 739 Failure code [CA234] (Engine overspeed)...................................................................................................... 739 Failure code [CA238] (Ne speed sensor power supply error).................................................................................... 740 Failure code [CA271] (PCV1 Short circuit).................................................................................................... 741 Failure code [CA272] (PCV1 Disconnection).................................................................................................... 742 Failure code [CA322] (Injector #1 (L/B #1) open/short error)................................................................................. 744 Failure code [CA323] (Injector #5 (L/B #5) open/short error)................................................................................. 746 Failure code [CA324] (Injector #3 (L/B #3) open/short error)................................................................................. 748 Failure code [CA325] (Injector #6 (L/B #6) open/short error)................................................................................. 750 Failure code [CA331] (Injector #2 (L/B #2) open/short error)................................................................................. 752 Failure code [CA332] (Injector #4 (L/B #4) open/short error)................................................................................. 754 Failure code [CA342] (Calibration code inconsistency)........................................................................................ 756 Failure code [CA351] (Injectors drive circuit error)......................................................................................... 757 Failure code [CA352] (Sensor power supply 1 low error)....................................................................................... 759 Failure code [CA386] (Sensor power supply 1 high error)...................................................................................... 761 Failure code [CA428] (Abnormally high level in water sensor)................................................................................. 762 Failure code [CA429] (Abnormally low level in water sensor).................................................................................. 764 Failure code [CA431] (Idle validation switch error).......................................................................................... 766 Failure code [CA432] (Idle validation action error).......................................................................................... 768 Failure code [CA435] (Engine oil pressure switch error)...................................................................................... 770 Failure code [CA441] (Battery voltage low error)............................................................................................. 771 Failure code [CA442] (Battery voltage high error)............................................................................................ 774 Failure code [CA449] Common rail pressure high error 2....................................................................................... 776 Failure code [CA451] (Common rail pressure sensor high error)................................................................................ 777 Failure code [CA452] (Common rail pressure sensor low error)................................................................................. 779 Failure code [CA488] (Derating of torque by abnormally high charge temperature).............................................................. 781 Failure code [CA553] (Common rail pressure high error 1)..................................................................................... 782 Failure code [CA559] (Supply pump pressure very low error)................................................................................... 783 Failure code [CA689] (Engine Ne speed sensor error).......................................................................................... 784 Failure code [CA731] (Engine Bkup speed sensor phase error).................................................................................. 786 Failure code [CA757] (All continuous data lost error)........................................................................................ 787 Failure code [CA778] (Engine Bkup speed sensor error)........................................................................................ 790 Failure code [CA1117] (Partial engine controller data loss error)............................................................................ 792 Failure code [CA1633] (KOMNET datalink timeout error)........................................................................................ 795 Troubleshooting by failure code (Display of code), Part 4............................................................................................ 799 Troubleshooting by failure code (Display of code), Part 4........................................................................................ 801 Failure code [CA2185] (Throttle sensor supply voltage high error)................................................................................ 801 Failure code [CA2186] (Throttle sensor power supply low error)................................................................................... 802 Failure code [CA2249] (Supply pump pressure very low error 2).................................................................................... 803 Failure code [CA2311] (Abnormality in IMV solenoid).............................................................................................. 804 Failure code [CA2555] (Intake heater relay disconnection error).................................................................................. 806 Failure code [CA2556] (Intake heater relay short circuit error).................................................................................. 808 Failure code [D150KA] (Emergency steering relay: Disconnection).................................................................................. 810 Failure code [D150KB] (Emergency steering relay: Short circuit).................................................................................. 812 Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)........................................................... 814 Failure code [D160KA] (Backup lamp relay: Disconnection)......................................................................................... 816 Failure code [D160KB] (Backup lamp relay: Short circuit)......................................................................................... 818 Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection).................................................................... 820 Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit).................................................................... 822 Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)............................................. 824 Failure code [D192KA] (ECSS solenoid: Disconnection)............................................................................................. 826 Failure code [D192KB] (ECSS solenoid: Short circuit)............................................................................................. 827 Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)...................................................................... 828 Failure code [D5ZHKA] (Terminal C signal: Disconnection)......................................................................................... 829 Failure code [D5ZHKB] (Terminal C signal: Short circuit)......................................................................................... 833 Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)................................................. 837 Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree).......................................................................... 840 Failure code [DAF3KK] (Machine monitor: Low source voltage (input)).............................................................................. 842 Failure code [DAF5KP] (Machine monitor: Low output voltage)...................................................................................... 844 Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))................. 847 Failure code [DAQ0KK] (Transmission controller: Low source voltage).............................................................................. 849 Failure code [DAQ0KT] (Transmission controller: Abnormality incontroller)........................................................................ 851 Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))............................................... 852 Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)......................................... 854 Troubleshooting by failure code (Display of code), Part 5............................................................................................ 857 Troubleshooting by failure code (Display of code), Part 5........................................................................................ 859 Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system))..... 859 Failure code [DAQRMA] (Transmission controller option setting:Malfunction)................................................................... 861 Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)............ 862 Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)................................... 865 Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)).... 866 Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)................................................................ 868 Failure code [DD15LD] switch (Panel switch 1): Switch is kept pressed for long time.......................................................... 870 Failure code [DD16LD] switch (Panel switch 2): Switch is kept pressed for long time.......................................................... 872 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time........................................................ 874 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time........................................................ 876 Failure code [DD1CLD] Load meter subtotal switch: Switch is keptpressed for long time........................................................ 878 Failure code [DD1FLD] Load meter mode selector switch (A/B): Switchis kept pressed for long time............................................. 880 Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time............................................ 882 Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)............................................. 884 Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)............................................................. 886 Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)................................................... 888 Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree).......................................................... 890 Troubleshooting by failure code (Display of code), Part 6............................................................................................ 895 Troubleshooting by failure code (Display of code), Part 6........................................................................................ 898 Failure code [DDK3KA] (Right FNR switch: Disconnection)...................................................................................... 898 Failure code [DDK6KA] (FNR lever switch: Disconnection)...................................................................................... 901 Failure code [DDK6KB] (FNR lever switch: Short circuit)...................................................................................... 904 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree).................................................................. 906 Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)................................................ 908 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)............................................................... 910 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time).................................................................... 912 Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)....................................................... 914 Failure code [DF10KA] (Transmission shift lever switch: Disconnected)........................................................................ 916 Failure code [DF10KB] (Transmission shift lever switch: Short circuit)....................................................................... 920 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected).................................................................... 922 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)................................................................... 924 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range).......................................................... 926 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)...................................................................... 928 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)......................................................... 930 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)................................................... 932 Troubleshooting by failure code (Display of code), Part 7............................................................................................ 935 Troubleshooting by failure code (Display of code), Part 7........................................................................................ 936 Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)...................................................... 936 Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)........................................................ 938 Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range).......................................................... 940 Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)............................................................................. 942 Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)............................................................................. 944 Troubleshooting by failure code (Display of code), Part 8............................................................................................ 947 Troubleshooting by failure code (Display of code), Part 8........................................................................................ 948 Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection).................................................................... 948 Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)........................................................ 950 Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)....................................................................... 952 Failure code [DV00KB] (Alarm buzzer: Short circuit).............................................................................................. 954 Troubleshooting by failure code (Display of code), Part 9............................................................................................ 957 Troubleshooting by failure code (Display of code), Part 9........................................................................................ 958 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection).................................................................................. 958 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit).................................................................................. 959 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)........................................................... 960 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)................................................................................. 962 Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)................................................................................. 963 Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line).......................................................... 964 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection).................................................................................. 966 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit).................................................................................. 968 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)........................................................... 970 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection).............................................................................. 972 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit).............................................................................. 974 Troubleshooting by failure code (Display of code), Part 10........................................................................................... 977 Troubleshooting by failure code (Display of code), Part 10....................................................................................... 980 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)....................................................... 980 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection).............................................................................. 982 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit).............................................................................. 984 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)....................................................... 986 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection).............................................................................. 988 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit).............................................................................. 990 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)....................................................... 992 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)................................................................................ 994 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)................................................................................ 996 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)......................................................... 998 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)................................................................................1000 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)................................................................................1002 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line).........................................................1004 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)..............................................................................1006 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)..............................................................................1008 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line).......................................................1010 Troubleshooting of electrical system (E-mode)........................................................................................................1013 Troubleshooting of electrical system (E-mode)....................................................................................................1015 Before carrying out troubleshooting for electrical system....................................................................................1015 Information in troubleshooting table.........................................................................................................1018 E-1 Engine does not start....................................................................................................................1019 E-2 Wiper does not operate...................................................................................................................1026 E-3 Windshield washer does not operate.......................................................................................................1030 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off..........................................................1033 E-5 Working lamp does not light up or go off.................................................................................................1041 E-6 Turn signal lamp and hazard lamp do not light up or go off...............................................................................1046 E-7 Brake lamp does not light or it keeps lighting up........................................................................................1052 E-8 Backup lamp does not light or it keeps lighting up.......................................................................................1054 E-9 Backup buzzer does not sound or it keeps sounding........................................................................................1056 E-10 Horn does not sound or it keeps sounding................................................................................................1058 E-11 Alarm buzzer does not sound or it keeps sounding........................................................................................1060 E-12 Air conditioner does not operate or stop................................................................................................1062 E-13 The KOMTRAX system does not work properly...............................................................................................1065 Troubleshooting of hydraulic and mechanical system (H-mode)..........................................................................................1069 Troubleshooting of hydraulic and mechanical system (H-mode)......................................................................................1071 Method of using troubleshooting chart........................................................................................................1071 Table of failure modes and causes............................................................................................................1074 H-1 The machine does not start...............................................................................................................1078 H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]...................................1080 H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]....................................................1081 H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted...................1082 H-5 Shocks are large at the times of starting and shifting gear..............................................................................1084 H-6 Time lag is large at the times of starting and shifting gear.............................................................................1086 H-7 The torque converter oil temperature is high.............................................................................................1088 H-8 Steering does not turn...................................................................................................................1089 H-9 Steering does not turn [Machine with joystick steering (if equipped)]....................................................................1090 H-10 Steering response is low................................................................................................................1091 H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]....................................................1092 H-12 Steering is heavy.......................................................................................................................1093 H-13 When machine turns, it shakes or makes large shocks.....................................................................................1094 H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]......................................1095 H-15 The wheel brake does not work or does not work well.....................................................................................1096 H-16 The wheel brake is not released or it drags.............................................................................................1097 H-17 The parking brake does not work or does not work well...................................................................................1098 H-18 The parking brake is not released or it drags (including emergency release system)......................................................1099 H-19 Lift arm does not rise..................................................................................................................1100 H-20 Lift arm speed is low or rising force of lift arm is insufficient.......................................................................1101 H-21 When rising, the lift arm comes to move slowly at specific height.......................................................................1102 H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats).......................................................................1102 H-23 Hydraulic drifts of the lift arm is large...............................................................................................1102 H-24 The lift arm wobbles during operation...................................................................................................1102 H-25 Bucket does not tilt back...............................................................................................................1103 H-26 Bucket speed is low or tilting back force is insufficient...............................................................................1104 H-27 The bucket comes to operate slowly in the midst of tilting-back.........................................................................1105 H-28 The bucket cylinder cannot hold down the bucket.........................................................................................1105 H-29 Hydraulic drifts of the bucket is large.................................................................................................1105 H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”).................................................1105 H-31 Lift arm and bucket control levers do not move smoothly and are heavy...................................................................1106 H-32 During operation of the machine, engine speed lowers remarkably or engine stalls........................................................1107 H-33 Large shock is made when work equipment starts and stops................................................................................1107 H-34 When work equipment circuit is relieved singly, other work equipment moves..............................................................1107 H-35 ECSS does not operate, and pitching, bouncing occur.....................................................................................1108 Troubleshooting of engine (S-mode)...................................................................................................................1111 Troubleshooting of engine (S-mode)...............................................................................................................1113 Method of using troubleshooting chart........................................................................................................1113 S-1 Engine does not start easily.............................................................................................................1116 S-2 Engine does not start....................................................................................................................1117 S-3 Engine does not pick up smoothly.........................................................................................................1120 S-4 Engine stops during operations...........................................................................................................1121 S-5 Engine does not rotate smoothly..........................................................................................................1122 S-6 Engine lacks output (or lacks power).....................................................................................................1123 S-7 Exhaust smoke is black (Incomplete combustion)...........................................................................................1124 S-8 Oil consumption is excessive (or exhaust smoke is blue)..................................................................................1125 S-9 Engine oil becomes contaminated quickly..................................................................................................1126 S-10 Fuel consumption is excessive...........................................................................................................1127 S-11 Coolant contains oil (blows back or reduces)............................................................................................1128 S-12 Oil pressure drops......................................................................................................................1129 S-13 Oil level rises (Water, fuel in oil)....................................................................................................1130 S-14 Coolant temperature rises too high (Overheating)........................................................................................1131 S-15 Abnormal noise is made..................................................................................................................1132 S-16 Vibration is excessive..................................................................................................................1133 50 Disassembly and assembly..............................................................................................................................1135 General information on disassembly and assembly......................................................................................................1135 General information on disassembly and assembly..................................................................................................1136 How to read this manual......................................................................................................................1136 Coating materials list.......................................................................................................................1138 Special tools list...........................................................................................................................1141 Engine and cooling system............................................................................................................................1145 Engine and cooling system........................................................................................................................1146 Removal and installation of fuel supply pump assembly........................................................................................1146 Removal and installation of fuel injector assembly...........................................................................................1148 Removal and installation of cylinder head assembly...........................................................................................1153 Removal and installation of engine hood......................................................................................................1162 Removal and installation of radiator assembly................................................................................................1164 Removal and installation of air aftercooler..................................................................................................1166 Removal and installation of hydraulic oil cooler assembly....................................................................................1168 Removal and installation of engine assembly..................................................................................................1170 Removal and installation of cooling fan and fan motor assembly...............................................................................1175 Removal and installation of fuel tank assembly...............................................................................................1178 Power train..........................................................................................................................................1181 Power train......................................................................................................................................1182 Removal and installation of torque converter and transmission assembly...........................................................................1182 Disassembly and assembly of torque converter assembly (Standard specification)...................................................................1188 Disassembly and assembly of torque converter assembly (Lockup specification).....................................................................1192 Disassembly and assembly of transmission assembly................................................................................................1198 Disassembly and assembly of transmission clutch pack assembly....................................................................................1213 Disassembly and assembly of parking brake assembly...............................................................................................1229 Removal and installation of front axle assembly..................................................................................................1234 Removal and installation of rear axle assembly...................................................................................................1236 Disassembly and assembly of axle housing.........................................................................................................1239 Disassembly and assembly of differential assembly................................................................................................1248 Steering system......................................................................................................................................1263 Steering system..................................................................................................................................1264 Removal and installation of steering demand valve assembly...................................................................................1264 Brake system.........................................................................................................................................1267 Brake system.....................................................................................................................................1268 Removal and installation of parking brake discs and plates.......................................................................................1268 Undercarriage and frame..............................................................................................................................1271 Undercarriage and frame..........................................................................................................................1272 Removal and installation of center hinge pin.....................................................................................................1272 Removal and installation of counterweight........................................................................................................1280 Hydraulic system.....................................................................................................................................1283 Hydraulic system.................................................................................................................................1284 Removal and installation of work equipment control valve assembly................................................................................1284 Removal and installation of power train pump and work equipment pump assembly....................................................................1286 Removal and installation of steering pump and cooling fan pump assembly..........................................................................1287 Removal and installation of hydraulic tank assembly..............................................................................................1288 Work equipment.......................................................................................................................................1293 Work equipment...................................................................................................................................1294 Removal and installation of work equipment assembly..............................................................................................1294 Disassembly and assembly of hydraulic cylinder assembly..........................................................................................1298 Cab and its attachments..............................................................................................................................1307 Cab and its attachments..........................................................................................................................1308 Removal and installation of operator's cab and floor frame assembly..........................................................................1308 Removal and installation of operator's cab glass (stuck glass)...............................................................................1311 Removal and installation of air conditioner unit assembly....................................................................................1319 Electrical system....................................................................................................................................1323 Electrical system................................................................................................................................1324 Removal and installation of engine controller assembly...........................................................................................1324 90 Diagrams and drawings.................................................................................................................................1327 Hydraulic diagrams and drawings......................................................................................................................1327 Hydraulic diagrams and drawings..................................................................................................................1328 Power train hydraulic circuit diagram........................................................................................................1328 Hydraulic circuit diagram....................................................................................................................1331 Electrical diagrams and drawings.....................................................................................................................1334 Electrical diagrams and drawings.................................................................................................................1336 Electrical circuit diagram (1/2).............................................................................................................1336 Electrical circuit diagram (2/2).............................................................................................................1337 Connector arrangement diagram................................................................................................................1338
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⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
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Sutton Cruz –
Good product highly recommended seller