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Komatsu WA380-6 Wheel Loader Shop Manual – PDFG DOWNLOAD
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Komatsu WA380-6 Wheel Loader Shop Manual
MACHINE MODEL SERIAL NUMBER
WA380-6 H60051 and up
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Description
Komatsu WA380-6 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA380-6 Wheel Loader Shop Manual
File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : VEBM440101
Total Pages : 1303
KOMATSU WA380-6 WHEEL LOADER SHOP MANUAL – PDFG DOWNLOAD:
DESCRIPTION:
Komatsu WA380-6 Wheel Loader Shop Manual
HOW TO READ THE SHOP MANUAL:
1. Composition of shop manual:
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 parts.
TABLE OF CONTENTS:
Komatsu WA380-6 Wheel Loader Shop Manual
VEBM440101 WA380-6................................................................................................................................... 1 00 Index and foreword................................................................................................................................ 3 Composition of shop manual....................................................................................................................... 4 Table of contents................................................................................................................................ 6 Index and foreword............................................................................................................................... 17 Safety notice................................................................................................................................ 18 How to read the shop manual.................................................................................................................. 23 Explanation of terms for maintenance standard................................................................................................ 25 Handling electric equipment and hydraulic component.......................................................................................... 27 How to read electric wire code............................................................................................................... 39 Precautions when carrying out operation...................................................................................................... 42 Method of disassembling and connecting push-pull type coupler................................................................................ 45 Standard tightening torque table............................................................................................................. 48 Conversion table............................................................................................................................. 52 01 Specification..................................................................................................................................... 57 Specification and technical data................................................................................................................. 59 Specification dimension drawing.............................................................................................................. 59 Specifications............................................................................................................................... 60 Weight table................................................................................................................................. 64 Table of fuel, coolant and lubricants........................................................................................................ 66 10 Structure, function and maintenance standard...................................................................................................... 67 Engine and cooling system........................................................................................................................ 68 Engine mount and transmission mount.......................................................................................................... 68 Cooling system............................................................................................................................... 69 Cooling fan pump............................................................................................................................. 70 Cooling fan motor............................................................................................................................ 78 Power train...................................................................................................................................... 87 Power train.................................................................................................................................. 87 Power train system diagram................................................................................................................... 88 Drive shaft.................................................................................................................................. 90 Power train piping diagram................................................................................................................... 91 Torque converter............................................................................................................................. 92 Transmission................................................................................................................................. 100 Flow control valve........................................................................................................................... 117 Valve assembly............................................................................................................................... 118 ECMV......................................................................................................................................... 119 Main relief valve and torque converter relief valve.......................................................................................... 126 Axle......................................................................................................................................... 128 Differential................................................................................................................................. 130 Limited slip differential.................................................................................................................... 135 Final drive.................................................................................................................................. 142 Steering system.................................................................................................................................. 146 Steering piping diagram...................................................................................................................... 146 Steering column.............................................................................................................................. 147 Steering pump................................................................................................................................ 148 Steering valve............................................................................................................................... 159 Orbit-roll valve............................................................................................................................. 174 Stop valve................................................................................................................................... 178 Steering relief valve........................................................................................................................ 179 Steering cylinder............................................................................................................................ 180 Emergency steering motor..................................................................................................................... 182 Emergency steering pump...................................................................................................................... 183 Brake system..................................................................................................................................... 186 Brake piping diagram......................................................................................................................... 186 Charge valve................................................................................................................................. 187 Brake valve.................................................................................................................................. 194 Accumulator (for brake)...................................................................................................................... 199 Brake........................................................................................................................................ 200 Parking brake control........................................................................................................................ 205 Parking brake................................................................................................................................ 206 Parking brake solenoid valve................................................................................................................. 208 Emergency parking brake release valve........................................................................................................ 210 Undercarriage and frame.......................................................................................................................... 212 Axle mount and center hinge pin.............................................................................................................. 212 Tires........................................................................................................................................ 216 Hydraulic system, Part 1......................................................................................................................... 218 Hydraulic piping diagram..................................................................................................................... 218 Work equipment control lever linkage......................................................................................................... 221 Hydraulic tank............................................................................................................................... 222 Power train pump............................................................................................................................. 224 Work equipment pump.......................................................................................................................... 225 Work equipment control valve................................................................................................................. 236 CLSS......................................................................................................................................... 250 Each function and operation of each valve.................................................................................................... 254 Hydraulic system, Part 2......................................................................................................................... 278 PPC valve.................................................................................................................................... 278 Stabilizer valve............................................................................................................................. 284 Accumulator (for PPC circuit)................................................................................................................ 289 Accumulator (for ECSS)....................................................................................................................... 290 Work equipment................................................................................................................................... 292 Work equipment linkage....................................................................................................................... 292 Bucket....................................................................................................................................... 294 Bucket positioner and boom kick-out.......................................................................................................... 295 Work equipment cylinder...................................................................................................................... 301 Cab and its attachments.......................................................................................................................... 305 Cab.......................................................................................................................................... 305 Air conditioner.............................................................................................................................. 306 Electrical system, Part 1........................................................................................................................ 320 Machine monitor system....................................................................................................................... 320 Machine monitor.............................................................................................................................. 325 Electrical system, Part 2........................................................................................................................ 348 Electrical system (Transmission controller system)........................................................................................... 348 Transmission controller...................................................................................................................... 382 Electrical system, Part 3........................................................................................................................ 386 Electric transmission control................................................................................................................ 386 Kickdown switch and hold switch.............................................................................................................. 390 KOMTRAX terminal system...................................................................................................................... 392 Engine starting circuit...................................................................................................................... 394 Engine stopping circuit...................................................................................................................... 396 Preheating circuit........................................................................................................................... 397 Engine power mode selector circuit........................................................................................................... 398 Engine output derating function.............................................................................................................. 399 Automatic warm-up function................................................................................................................... 399 Parking brake circuit........................................................................................................................ 400 Sensor....................................................................................................................................... 402 Standard service value table..................................................................................................................... 412 Standard service value table for engine...................................................................................................... 412 Standard service value table for chassis..................................................................................................... 413 20 Standard value table.............................................................................................................................. 411 Standard service value table..................................................................................................................... 412 30 Testing and adjusting............................................................................................................................. 421 Testing and adjusting, Part 1.................................................................................................................... 423 Tools for testing, adjusting, and troubleshooting............................................................................................ 423 Measuring engine speed....................................................................................................................... 426 Measuring exhaust gas color.................................................................................................................. 428 Adjusting valve clearance.................................................................................................................... 430 Measuring compression pressure............................................................................................................... 432 Measuring blow-by pressure................................................................................................................... 435 Measuring engine oil pressure................................................................................................................ 436 Measuring intake air (boost) pressure........................................................................................................ 437 Handling fuel system equipment............................................................................................................... 438 Releasing residual pressure in fuel system................................................................................................... 438 Measuring fuel pressure...................................................................................................................... 439 Measuring fuel return rate and leakage....................................................................................................... 441 Bleeding air from fuel circuit............................................................................................................... 444 Testing leakage in fuel system............................................................................................................... 446 Handling reduced cylinder mode operation..................................................................................................... 447 Handling no-injection cranking operation..................................................................................................... 447 Handling controller voltage circuit.......................................................................................................... 448 Testing and adjusting air conditioner compressor belt tension................................................................................ 449 Adjusting transmission speed sensor.......................................................................................................... 450 Measuring directional lever.................................................................................................................. 451 Measuring and adjusting power train oil pressure............................................................................................. 452 Procedure for flushing torque converter and transmission hydraulic circuit................................................................... 467 Method of moving machine when transmission valve is broken................................................................................... 468 Testing and adjusting steering stop valve.................................................................................................... 470 Testing and adjusting steering wheel......................................................................................................... 472 Testing steering oil pressure................................................................................................................ 474 Bleeding air from steering circuit........................................................................................................... 477 Testing and adjusting, Part 2.................................................................................................................... 481 Testing hydraulic drive fan.................................................................................................................. 481 Bleeding air from hydraulic drive fan circuit................................................................................................ 483 Measuring brake pedal........................................................................................................................ 485 Measuring brake performance.................................................................................................................. 486 Testing and adjusting accumulator charge pressure............................................................................................ 487 Testing wheel brake oil pressure............................................................................................................. 488 Measuring wear of wheel brake disc........................................................................................................... 490 Bleeding air from wheel brake circuit........................................................................................................ 491 Releasing residual pressure in brake accumulator circuit..................................................................................... 492 Testing parking brake performance............................................................................................................ 493 Measuring parking brake oil pressure......................................................................................................... 494 Testing wear of parking brake disc........................................................................................................... 496 Method of releasing parking brake manually................................................................................................... 497 Measuring and adjusting work equipment control lever......................................................................................... 498 Measuring and adjusting work equipment PPC oil pressure...................................................................................... 499 Measuring and adjusting work equipment oil pressure.......................................................................................... 502 Bleeding air from work equipment circuit..................................................................................................... 506 Releasing residual pressure in work equipment circuit........................................................................................ 507 Testing and adjusting bucket positioner...................................................................................................... 508 Testing and adjusting boom kick- out......................................................................................................... 510 Checking proximity switch operation pilot lamp............................................................................................... 511 Procedure for testing diodes................................................................................................................. 512 Preparation work for troubleshooting for electric system..................................................................................... 513 How to start operation of KOMTRAX terminal................................................................................................... 518 Lamp display of KOMTRAX terminal............................................................................................................. 523 Adjusting machine monitor.................................................................................................................... 526 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor....................................................... 527 Testing and adjusting, Part 3.................................................................................................................... 530 Special functions of machine monitor (EMMS).................................................................................................. 530 Pm-click inspection table.................................................................................................................... 589 40 Troubleshooting................................................................................................................................... 591 General information on troubleshooting........................................................................................................... 592 Points to remember when troubleshooting...................................................................................................... 592 Sequence of events in troubleshooting........................................................................................................ 593 Testing before troubleshooting............................................................................................................... 594 Classification and procedures of troubleshooting............................................................................................. 595 Connection table for connector pin numbers................................................................................................... 598 T-branch box and T-branch adapter table...................................................................................................... 621 Troubleshooting by failure code (Display of code), Part 1........................................................................................ 627 Failure codes list........................................................................................................................... 627 Before carrying out troubleshooting for electrical system.................................................................................... 634 Information contained troubleshooting table.................................................................................................. 637 Failure code [1500L0] (TORQFLOW transmission: Double meshing)................................................................................ 639 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)........................................................ 640 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)........................................................ 642 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)........................................................ 644 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)........................................................ 646 Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)...................................................... 648 Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)...................................................... 650 Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)...................................................... 652 Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)...................................................... 654 Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)...................................................... 656 Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)...................................................... 658 Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)...................................................... 660 Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)...................................................... 662 Failure code [2F00MA] (Parking brake: Malfunction)........................................................................................... 664 Troubleshooting by failure code (Display of code), Part 2........................................................................................ 670 Failure code [2G43ZG] (Accumulator: Low oil pressure)........................................................................................ 670 Failure code [AA1ANX] (Air cleaner: Clogging)................................................................................................ 672 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine).......................................................... 674 Failure code [AB00MA] (Alternator: Malfunction).............................................................................................. 676 Failure code [B@BAZG] (Rotation derating by low engine oil pressure)......................................................................... 678 Failure code [B@BAZK] (Engine oil: Low level)................................................................................................ 679 Failure code [B@BCNS] (Coolant: Overheating)................................................................................................. 680 Failure code [B@BCZK] (Coolant: Low level)................................................................................................... 682 Failure code [B@C7NS] (Brake oil: Overheating)............................................................................................... 684 Failure code [b@CENS] (Torque converter oil: Overheating).................................................................................... 686 Failure code [B@CENS] (Torque converter oil: Overheating).................................................................................... 688 Failure code [B@HANS] (Hydraulic oil: Overheating)........................................................................................... 690 Failure code [CA111] (Abnormality in engine controller)...................................................................................... 692 Failure code [CA115] (Engine Ne or Bkup speed sensor error).................................................................................. 693 Failure code [CA122] (Charge pressure sensor high error)..................................................................................... 694 Failure code [CA123] (Charge pressure sensor low error)...................................................................................... 696 Failure code [CA131] (Throttle sensor high error)............................................................................................ 698 Failure code [CA132] (Throttle sensor low error)............................................................................................. 700 Failure code [CA144] (Coolant sensor high error)............................................................................................. 702 Failure code [CA145] (Coolant sensor low error).............................................................................................. 704 Failure code [CA153] (Charge temperature sensor high error).................................................................................. 706 Failure code [CA154] (Charge temperature sensor low error)................................................................................... 708 Failure code [CA155] (Derating of speed by abnormally high charge temperature)............................................................... 710 Failure code [CA187] (Sensor power supply 2 low error)....................................................................................... 712 Failure code [CA221] (Atmospheric pressure sensor high error)................................................................................ 714 Failure code [CA222] (Atmospheric sensor low error).......................................................................................... 716 Failure code [CA227] (Sensor power supply 2 high error)...................................................................................... 718 Troubleshooting by failure code (Display of code), Part 3........................................................................................ 721 Failure code [CA234] (Engine overspeed)...................................................................................................... 721 Failure code [CA238] (Ne speed sensor power supply error).................................................................................... 722 Failure code [CA271] (PCV1 Short circuit).................................................................................................... 723 Failure code [CA272] (PCV1 Disconnection).................................................................................................... 724 Failure code [CA322] (Injector #1 (L/B #1) open/short error)................................................................................. 726 Failure code [CA323] (Injector #5 (L/B #5) open/short error)................................................................................. 728 Failure code [CA324] (Injector #3 (L/B #3) open/short error)................................................................................. 730 Failure code [CA325] (Injector #6 (L/B #6) open/short error)................................................................................. 732 Failure code [CA331] (Injector #2 (L/B #2) open/short error)................................................................................. 734 Failure code [CA332] (Injector #4 (L/B #4) open/short error)................................................................................. 736 Failure code [CA342] (Calibration code inconsistency)........................................................................................ 738 Failure code [CA351] (Injectors drive circuit error)......................................................................................... 739 Failure code [CA352] (Sensor power supply 1 low error)....................................................................................... 741 Failure code [CA386] (Sensor power supply 1 high error)...................................................................................... 743 Failure code [CA428] (Abnormally high level in water sensor)................................................................................. 744 Failure code [CA429] (Abnormally low level in water sensor).................................................................................. 746 Failure code [CA431] (Idle validation switch error).......................................................................................... 748 Failure code [CA432] (Idle validation action error).......................................................................................... 750 Failure code [CA435] (Engine oil pressure switch error)...................................................................................... 752 Failure code [CA441] (Battery voltage low error)............................................................................................. 753 Failure code [CA442] (Battery voltage high error)............................................................................................ 756 Failure code [CA449] Common rail pressure high error 2....................................................................................... 758 Failure code [CA451] (Common rail pressure sensor high error)................................................................................ 759 Failure code [CA452] (Common rail pressure sensor low error)................................................................................. 761 Failure code [CA488] (Derating of torque by abnormally high charge temperature).............................................................. 763 Failure code [CA553] (Common rail pressure high error 1)..................................................................................... 764 Failure code [CA559] (Supply pump pressure very low error)................................................................................... 765 Failure code [CA689] (Engine Ne speed sensor error).......................................................................................... 766 Failure code [CA731] (Engine Bkup speed sensor phase error).................................................................................. 768 Failure code [CA757] (All continuous data lost error)........................................................................................ 769 Failure code [CA778] (Engine Bkup speed sensor error)........................................................................................ 772 Failure code [CA1117] (Partial engine controller data loss error)............................................................................ 774 Failure code [CA1633] (KOMNET datalink timeout error)........................................................................................ 777 Troubleshooting by failure code (Display of code), Part 4........................................................................................ 781 Failure code [CA2185] (Throttle sensor supply voltage high error)............................................................................ 781 Failure code [CA2186] (Throttle sensor power supply low error)............................................................................... 782 Failure code [CA2249] (Supply pump pressure very low error 2)................................................................................ 783 Failure code [CA2311] (Abnormality in IMV solenoid).......................................................................................... 784 Failure code [CA2555] (Intake heater relay disconnection error).............................................................................. 786 Failure code [CA2556] (Intake heater relay short circuit error).............................................................................. 788 Failure code [D150KA] (Emergency steering relay: Disconnection).............................................................................. 790 Failure code [D150KB] (Emergency steering relay: Short circuit).............................................................................. 792 Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)....................................................... 794 Failure code [D160KA] (Backup lamp relay: Disconnection)..................................................................................... 796 Failure code [D160KB] (Backup lamp relay: Short circuit)..................................................................................... 798 Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)................................................................ 800 Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)................................................................ 802 Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)......................................... 804 Failure code [D192KA] (ECSS solenoid: Disconnection)......................................................................................... 806 Failure code [D192KB] (ECSS solenoid: Short circuit)......................................................................................... 807 Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line).................................................................. 808 Failure code [D5ZHKA] (Terminal C signal: Disconnection)..................................................................................... 809 Failure code [D5ZHKB] (Terminal C signal: Short circuit)..................................................................................... 813 Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)............................................. 817 Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)...................................................................... 820 Failure code [DAF3KK] (Machine monitor: Low source voltage (input)).......................................................................... 822 Failure code [DAF5KP] (Machine monitor: Low output voltage).................................................................................. 824 Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))............. 827 Failure code [DAQ0KK] (Transmission controller: Low source voltage).......................................................................... 829 Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)................................................................... 831 Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))........................................... 832 Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)..................................... 834 Troubleshooting by failure code (Display of code), Part 5........................................................................................ 837 Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system))..... 837 Failure code [DAQRMA] (Transmission controller option setting: Malfunction).................................................................. 839 Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)............ 840 Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)................................... 843 Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)).... 844 Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)................................................................ 846 Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time........................................................ 848 Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time........................................................ 850 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time........................................................ 852 Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time........................................................ 854 Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time....................................................... 856 Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time............................................ 858 Failure code [DD1GLD] Load meter mode selector switch (+/-): Switch is kept pressed for long time............................................ 860 Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)............................................. 862 Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)............................................................. 864 Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)................................................... 866 Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree).......................................................... 868 Troubleshooting by failure code (Display of code), Part 6........................................................................................ 874 Failure code [DDK3KA] (Right FNR switch: Disconnection)...................................................................................... 874 Failure code [DDK6KA] (FNR lever switch: Disconnection)...................................................................................... 877 Failure code [DDK6KB] (FNR lever switch: Short circuit)...................................................................................... 880 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree).................................................................. 882 Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)................................................ 884 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)............................................................... 886 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time).................................................................... 888 Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)....................................................... 890 Failure code [DF10KA] (Transmission shift lever switch: Disconnected)........................................................................ 892 Failure code [DF10KB] (Transmission shift lever switch: Short circuit)....................................................................... 896 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected).................................................................... 898 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)................................................................... 900 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range).......................................................... 902 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)...................................................................... 904 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)......................................................... 906 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)................................................... 908 Troubleshooting by failure code (Display of code), Part 7........................................................................................ 912 Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range).................................................. 912 Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range).................................................... 914 Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)...................................................... 916 Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)......................................................................... 918 Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)......................................................................... 920 Troubleshooting by failure code (Display of code), Part 8........................................................................................ 924 Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)................................................................ 924 Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range).................................................... 926 Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)................................................................... 928 Failure code [DV00KB] (Alarm buzzer: Short circuit).......................................................................................... 930 Troubleshooting by failure code (Display of code), Part 9........................................................................................ 934 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection).................................................................................. 934 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit).................................................................................. 935 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)........................................................... 936 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)................................................................................. 938 Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)................................................................................. 939 Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line).......................................................... 940 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection).................................................................................. 942 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit).................................................................................. 944 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)........................................................... 946 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection).............................................................................. 948 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit).............................................................................. 950 Troubleshooting by failure code (Display of code), Part 10....................................................................................... 956 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)....................................................... 956 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection).............................................................................. 958 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit).............................................................................. 960 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)....................................................... 962 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection).............................................................................. 964 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit).............................................................................. 966 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)....................................................... 968 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)................................................................................ 970 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)................................................................................ 972 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)......................................................... 974 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)................................................................................ 976 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)................................................................................ 978 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)......................................................... 980 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection).............................................................................. 982 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit).............................................................................. 984 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)....................................................... 986 Troubleshooting of electrical system (E-mode).................................................................................................... 991 Before carrying out troubleshooting for electrical system.................................................................................... 991 Information in troubleshooting table......................................................................................................... 994 E-1 Engine does not start.................................................................................................................... 995 E-2 Wiper does not operate...................................................................................................................1002 E-3 Windshield washer does not operate.......................................................................................................1006 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off..........................................................1010 E-5 Working lamp does not light up or go off.................................................................................................1018 E-6 Turn signal lamp and hazard lamp do not light up or go off...............................................................................1023 E-7 Brake lamp does not light or it keeps lighting up........................................................................................1029 E-8 Backup lamp does not light or it keeps lighting up.......................................................................................1031 E-9 Backup buzzer does not sound or it keeps sounding........................................................................................1033 E-10 Horn does not sound or it keeps sounding................................................................................................1035 E-11 Alarm buzzer does not sound or it keeps sounding........................................................................................1038 E-12 Air conditioner does not operate or stop................................................................................................1040 E-13 The KOMTRAX system does not work properly...............................................................................................1043 Troubleshooting of hydraulic and mechanical system (H-mode)......................................................................................1047 Method of using troubleshooting chart........................................................................................................1047 Table of failure modes and causes............................................................................................................1050 H-1 The machine does not start...............................................................................................................1054 H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]...................................1056 H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]....................................................1057 H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted...................1058 H-5 Shocks are large at the times of starting and shifting gear..............................................................................1060 H-6 Time lag is large at the times of starting and shifting gear.............................................................................1062 H-7 The torque converter oil temperature is high.............................................................................................1064 H-8 Steering does not turn...................................................................................................................1065 H-9 Steering does not turn [Machine with joystick steering (if equipped)]....................................................................1066 H-10 Steering response is low................................................................................................................1067 H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]....................................................1068 H-12 Steering is heavy.......................................................................................................................1069 H-13 When machine turns, it shakes or makes large shocks.....................................................................................1070 H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]......................................1071 H-15 The wheel brake does not work or does not work well.....................................................................................1072 H-16 The wheel brake is not released or it drags.............................................................................................1073 H-17 The parking brake does not work or does not work well...................................................................................1074 H-18 The parking brake is not released or it drags (including emergency release system)......................................................1075 H-19 Lift arm does not rise..................................................................................................................1076 H-20 Lift arm speed is low or rising force of lift arm is insufficient.......................................................................1077 H-21 When rising, the lift arm comes to move slowly at specific height.......................................................................1078 H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats).......................................................................1078 H-23 Hydraulic drifts of the lift arm is large...............................................................................................1078 H-24 The lift arm wobbles during operation...................................................................................................1078 H-25 Bucket does not tilt back...............................................................................................................1079 H-26 Bucket speed is low or tilting back force is insufficient...............................................................................1080 H-27 The bucket comes to operate slowly in the midst of tilting-back.........................................................................1081 H-28 The bucket cylinder cannot hold down the bucket.........................................................................................1081 H-29 Hydraulic drifts of the bucket is large.................................................................................................1081 H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”).................................................1081 H-31 Lift arm and bucket control levers do not move smoothly and are heavy...................................................................1082 H-32 During operation of the machine, engine speed lowers remarkably or engine stalls........................................................1083 H-33 Large shock is made when work equipment starts and stops................................................................................1083 H-34 When work equipment circuit is relieved singly, other work equipment moves..............................................................1083 H-35 ECSS does not operate, and pitching, bouncing occur.....................................................................................1084 Troubleshooting of engine (S-mode)...............................................................................................................1087 Method of using troubleshooting chart........................................................................................................1087 S-1 Engine does not start easily.............................................................................................................1090 S-2 Engine does not start....................................................................................................................1091 S-3 Engine does not pick up smoothly.........................................................................................................1094 S-4 Engine stops during operations...........................................................................................................1095 S-5 Engine does not rotate smoothly..........................................................................................................1096 S-6 Engine lacks output (or lacks power).....................................................................................................1097 S-7 Exhaust smoke is black (Incomplete combustion)...........................................................................................1098 S-8 Oil consumption is excessive (or exhaust smoke is blue)..................................................................................1099 S-9 Engine oil becomes contaminated quickly..................................................................................................1100 S-10 Fuel consumption is excessive...........................................................................................................1101 S-11 Coolant contains oil (blows back or reduces)............................................................................................1102 S-12 Oil pressure drops......................................................................................................................1103 S-13 Oil level rises (Water, fuel in oil)....................................................................................................1104 S-14 Coolant temperature rises too high (Overheating)........................................................................................1105 S-15 Abnormal noise is made..................................................................................................................1106 S-16 Vibration is excessive..................................................................................................................1107 50 Disassembly and assembly..........................................................................................................................1109 General information on disassembly and assembly..................................................................................................1110 How to read this manual......................................................................................................................1110 Coating materials list.......................................................................................................................1112 Special tools list...........................................................................................................................1115 Engine and cooling system........................................................................................................................1118 Removal and installation of fuel supply pump assembly........................................................................................1118 Removal and installation of fuel injector assembly...........................................................................................1120 Removal and installation of cylinder head assembly...........................................................................................1125 Removal and installation of engine hood......................................................................................................1134 Removal and installation of radiator assembly................................................................................................1136 Removal and installation of air aftercooler..................................................................................................1138 Removal and installation of hydraulic oil cooler assembly....................................................................................1140 Removal and installation of engine assembly..................................................................................................1142 Removal and installation of cooling fan and fan motor assembly...............................................................................1147 Removal and installation of fuel tank assembly...............................................................................................1150 Power train......................................................................................................................................1154 Removal and installation of torque converter and transmission assembly.......................................................................1154 Disassembly and assembly of torque converter assembly (Standard specification)...............................................................1160 Disassembly and assembly of torque converter assembly (Lockup specification).................................................................1164 Disassembly and assembly of transmission assembly............................................................................................1170 Disassembly and assembly of transmission clutch pack assembly................................................................................1185 Disassembly and assembly of parking brake assembly...........................................................................................1201 Removal and installation of front axle assembly..............................................................................................1206 Removal and installation of rear axle assembly...............................................................................................1208 Disassembly and assembly of axle housing.....................................................................................................1211 Disassembly and assembly of differential assembly............................................................................................1220 Steering system..................................................................................................................................1234 Removal and installation of steering demand valve assembly...................................................................................1234 Brake system.....................................................................................................................................1238 Removal and installation of parking brake discs and plates...................................................................................1238 Undercarriage and frame..........................................................................................................................1242 Removal and installation of center hinge pin.................................................................................................1242 Removal and installation of counterweight....................................................................................................1250 Hydraulic system.................................................................................................................................1254 Removal and installation of work equipment control valve assembly............................................................................1254 Removal and installation of power train pump and work equipment pump assembly................................................................1256 Removal and installation of steering pump and cooling fan pump assembly......................................................................1257 Removal and installation of hydraulic tank assembly..........................................................................................1258 Work equipment...................................................................................................................................1262 Removal and installation of work equipment assembly..........................................................................................1262 Disassembly and assembly of hydraulic cylinder assembly......................................................................................1266 Cab and its attachments..........................................................................................................................1276 Removal and installation of operator's cab and floor frame assembly..........................................................................1276 Removal and installation of operator's cab glass (stuck glass)...............................................................................1279 Removal and installation of air conditioner unit assembly....................................................................................1287 Electrical system................................................................................................................................1292 Removal and installation of engine controller assembly.......................................................................................1292 90 Diagrams and drawings.............................................................................................................................1293 Hydraulic diagrams and drawings..................................................................................................................1293 Hydraulic diagrams and drawings..............................................................................................................1294 Power train hydraulic circuit diagram....................................................................................................1294 Hydraulic circuit diagram....................................................................................................................1297 Electrical diagrams and drawings.................................................................................................................1301 Electrical circuit diagram (1/2).............................................................................................................1301 Electrical circuit diagram (2/2).............................................................................................................1302 Connector arrangement diagram................................................................................................................1303
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